Stuck. It’s a word that’s chilling to the most experienced off-roaders, and it’s downright terrifying if you’re the type who frequently goes solo in the backcountry. Sure, there are ways to get un-stuck using rudimentary equipment and strokes of genius, but it’s better to equip yourself for self-recovery before you even leave your driveway.
As an adventurer who frequently flies solo in the dirt, I’d successfully relied on a combination of skill and dumb luck to keep myself un-stuck. At the same time, everyone’s got a creek crossing, a mudhole, or a high-center spot with his or her name on it, and it was merely a matter of time before I found mine.
All the while, there’s been a Warn 9.5 XP winch lying fallow in the garage. It was time to put it to use before my backcountry luck took a turn for the worse.
The Warn 9.5 XP was left over...
The Warn 9.5 XP was left over from a previous project vehicle, and was in generally good shape. Just to be safe, we shipped the winch back to Warn Industries for an inspection and some updates. It came back as a practically brand new Warn 9.5 XP-S. A sturdy shipping container is a must, so steel tubing and angle iron were pressed into service for the occasion. The container was then wrapped with clear shrink-wrap to keep the weather out. A steel container isn’t mandatory. A strong one is.
Even with a working winch, no self-recovery package is complete without a selection of key winching accessories. Warn Industries not only makes premium winches, but also offers a wide selection of winching accessories. Winching accessories make self-recovery safer, more successful, and can also eliminate damage to trees and other trailside features.
Let’s see: working winch? Check. Winching accessories? Check again. What’s missing? A winch bumper!
Even though there are ready-made winch bumpers available for my ’04 4Runner, I decided to take on the challenge of building my own. A Warn universal trailer mounting system was the perfect starting point for a home-brewed winch bumper.
This time, we’ll take a look at the winch itself, check out a selection of winching accessories, and start the winch bumper.
Next time, we’ll complete the bumper build.
Finally, we’ll take the whole system on the trail where it belongs and demonstrate safe and effective winching techniques.
Here’s part one of our three-step empowerment program.
Warn’s ability to service...
Warn’s ability to service and upgrade existing Warn winches is impressive. It means your Warn winch is a long-term investment that won’t end with a minor problem or a broken part. To change the old XP into the new XP-S, Warn swapped the motor, drum, contactor, and remote control.
Compared to the old XP, the...
Compared to the old XP, the XP-S contactor box’s remote-control connection is better sealed against the elements than its predecessor. The connection is a D-shaped coupler that’s easy to orient and clip into place.
Even though the bumper was...
Even though the bumper was going to be fabricated from scratch, it made sense to incorporate Warn’s universal trailer mount as the centerpiece. This is the “foot down” version. Warn also makes a foot-forward universal mount to accommodate different mounting needs. You can get the mount with a solenoid bracket and mounting hardware, or buy the plate a la carte if you don’t need the other items.
The Warn 9.5 XP-S features...
The Warn 9.5 XP-S features 9,500 pounds of pulling power and is wound with Warn’s Spydura synthetic rope. Warn’s polished aluminum Hawse fairlead is the perfect match for the synthetic winch line. If you’d rather, Warn offers the 9.5 XP with a steel rope and a roller fairlead. The two Warn hooks are slated to be a part of the new bumper.
Choices are good, and being...
Choices are good, and being able to buy items a la carte is good, too. However, Warn makes choosing winching accessories intuitive and easy with pre-packaged accessory kits. This is the Medium-Duty Winching Accessories Kit, and is designed to be a companion for the 9.5 XP-S and other Warn winches of the same capacity. Inside the heavy-duty camo bag you’ll find a recovery strap, a tree trunk protector, a pair of clevises, a pair of Warn gloves, and a snatch block. Warn’s winching techniques safety guidebook was also inside.
On the left is a 3-inch-wide,...
On the left is a 3-inch-wide, 35-foot-long recovery strap. It’s rated to 21,600 pounds and is more forgiving than a steel chain. On the right is a tree trunk protector strap. Never wrap a winch line directly around a tree. You’ll damage the bark which can injure or kill the tree and injure or kill trail access.
The snatch block is no lightweight!...
The snatch block is no lightweight! This sucker is sturdy and substantial. The keychain should provide some sense of scale.
The snatch block’s pulley...
The snatch block’s pulley features a zerk fitting for easy maintenance. This feature was as slick as it was safe: the three lines will distort if the steel gets stretched. Once the lines aren’t straight it indicates that the steel is stretched and the snatch block should be replaced.
Information is as valuable...
Information is as valuable as equipment. Warn’s “Basic Guide to Winching Techniques” is available a la carte, as well, or you can download it free of charge from the Warn website.
Even with the accessory kit,...
Even with the accessory kit, there were a few other Warn items needed to round out our self-recovery arsenal. This shackle bracket fits a Class III hitch and includes the shackle. You’ll need to order the pin separately. There’s a factory hitch receiver on the back of the 4Runner; this is the perfect matchup.
If you’re anchoring to something...
If you’re anchoring to something sharp or abrasive that might damage a tree trunk protector strap you should use a choker chain instead. The choker chain can also be used to link vehicles together to form a super-strong winching anchor point. Since the chain has zero elasticity you shouldn’t use it for a recovery strap. Each accessory has a definite purpose.
The prerunner-style bumper...
The prerunner-style bumper on the 4Runner was custom-built by Desolate Motorsports in Whittier, California. It bolts to stock mounts and the style goes hand-in-glove with the rest of the ‘Runner. The approach angle is ideal, too. The new bumper will be inspired by this one.
The stock bumper mounting...
The stock bumper mounting points are perfectly fine for holding a general-purpose bumper, but not exactly confidence-inspiring when it comes to withstanding a hard winch pull. The front plates are fairly thin, and the side bolts (hidden behind the shock reservoir) anchor to a vulnerable part of the frame.
Not only are the front bumper...
Not only are the front bumper plates thin, they’re stitch welded instead of continuously welded to the frame. Again, not exactly confidence-inspiring.
Part of the process is to...
Part of the process is to stand back and brainstorm.
The frame features a cradle...
The frame features a cradle that runs underneath the radiator and air conditioning condenser. Tying the cradle to the A-arm crossmember will add a lot of strength.
The parts are cut, cleaned,...
The parts are cut, cleaned, and ready for welding.
The angled tube end caps create...
The angled tube end caps create a finished look but don’t do much else. After the end caps were welded on, the next steps were to weld the stubby tube in place and tack weld it to the frame plate.
The fit was then checked on...
The fit was then checked on the vehicle. Paint will be removed prior to welding on the frame.
Satisfied with the fit, the...
Satisfied with the fit, the next move was to weld the plate to the tube. Welding the flat plate to the A-arm crossmember is simple compared to trying to weld the whole assembly on the vehicle. Planning ahead and doing things in order makes life easier.
Here’s the basic shape of...
Here’s the basic shape of the main bumper structure and the winch mounting system.
The main tube will become the frame’s front crossmember, and the winch mount can be bolted on or detached as desired. The winch mount hasn’t been completely welded in these photos, but will be during the next fabrication session. More tubing and plate will be added to this assembly to make the complete bumper system.