Fitting a winch to TJM T13 bar

[fido666 Banned Find all posts View Profile Close fido666]

Well we almost got there only to find the bolts that come with the winch are too long. They hit the base of the winch before they can be done up all the way. I'm assuming these are high tensile bolts and not something you can just buy at the local hardware store. Now what do we do?

[AJ120 Out of control poster! Find all posts View Profile Close AJ120]

Its easy to tell if they are high tensile, I would assume they are Metric, in which case they will most likely have 8.8 on the head, possibly 10.9 but thats less likely, both are high tensile bolts. If it is imperial a high tensile bolt will either have 3 lines (grade 5) or 6 lines (Grade 8) radiating from the middle of the head.

Either way most hardware stores stock HT bolts in grab packs, take one of the bolts with you as they usually have a spot to check the thread type and pitch on the bolt stand.

Otherwise, use a few washers to pack it out, then when you can get bolts remove them one at a time and replace with correct bolts.

Cheers Andrew

[fido666 Banned Find all posts View Profile Close fido666]

Just checked the bolts Andrew, they are labelled "DG 8.8" and are approx 40mm long. I'm not sure how much shorter they need to be. I did see mention in the 4WDTV vid on YouTube of using a spacer bar (straight metal pate with 2 holes drilled in it) but they were using an ARB bar, they didn't say if it came with the bar. Is it possible to shorten the bolts with a hacksaw or will that most likely wreck them?

[AJ120 Out of control poster! Find all posts View Profile Close AJ120]

They are high tensile then, although 8.8 is a run of the mill (grade 5 equivelant) bolt so not as good as a 12.9 (grade 8) and cutting it with a hacksaw should be possible, certainly a cut off wheel in an angle grinder will do the trick, just clean up the end of the thread with a file or a bench grinder and they should be OK. If they are no good to you anyway you have nothing to loose by trying.

Cheers Andrew

[mjrandom Out of control poster! Find all posts View Profile Close mjrandom]

I picked up my ramps for $5 from a garage sale, so bargains can be had if your lucky sometimes

Way off topic but a mate of mine picked up a white left handed Fender Stratocaster at a garage sale in Melbourne a few years ago. It belonged to a son who was no longer with us and the parents were ridding the place of stuff. Had a scrawled signature on it. Mate bought the guitar for $50. It was a limited edition Hendrix autographed Strat. Mongel. At least he can't play it.

Back on topic there is no problem shortening HT bolts. Just make sure they don't get too hot if you cut them with an angle grinder and don't water quench them if you do. Otherwise no problems, actually unlikely to be any problems anyway but take it easy. Also file or gently grind a nice chamfer where you cut the bolt to lead into the thread. Likely the threads are rolled and not cut but it makes no difference.

[fido666 Banned Find all posts View Profile Close fido666]

TJM fit mine without having to pull bar off.

They removed the grill and got it in - mako tds - which was too big for my mates patrol bar.

They keep telling me the bar has to come off but having now slotted the winch into position I know that's not true. With your Mako where did they end up putting the control box? The one on the Tigerz11 Grande is massive and only comes with an angled mount bracket that looks like it's meant to go on the top of the bullbar (i.e. between the spotties). I can't do that with mine because I have the front camera.

cutting it with a hacksaw should be possible, certainly a cut off wheel in an angle grinder will do the trick, just clean up the end of the thread with a file or a bench grinder and they should be OK.

Is it likely to be very hard work to go the hacksaw route?

Back on topic there is no problem shortening HT bolts. Just make sure they don't get too hot if you cut them with an angle grinder and don't water quench them if you do.

I think I own an angle grinder but have never used one so I'm not sure how to go about it. I'm assuming "water quench" just means pouring cold water over the bolts to cool them down which is not a good thing.

[mjrandom Out of control poster! Find all posts View Profile Close mjrandom]

I am assuming the bolts are M12s in which case a hacksaw isn't too bad. If you are right handed put the bolt in the right hand side of the jaws. If you can thread a nut on the bit that you want to keep. This will prevent the hacksaw chopping into thread you need and also when the cut is finished you can unthread the nut and it will open up the thread before you file the chamfer. If you haven't used your angle grinder I am guessing it is fitted with a grinding disc as opposed to the thinner cutting disc, in that case you are probably better off with a hacksaw. And yes dipping the very hot bolt in water. Depends how hot the bolt became during cutting but quenching can alter the microstructure and make the bolt more brittle, unlikely but possible. This isn't the place for a materials lecture.

[fido666 Banned Find all posts View Profile Close fido666]

OK thanks for the explanation MJ. The other problem I face is where to fit the solenoid box as I mentioned above. I've seen posts before where people have mounted them in the engine bay but can't seem to locate them now.

After having tried twice now to fit the winch I'm about ready to give in and let TJM do the job, would be so much easier. Part of the problem is not having the right tools for cutting things and fabricating brackets, etc. After all the trouble I went to to get the bash plate removed this latest setback is very disheartening.

[AJ120 Out of control poster! Find all posts View Profile Close AJ120]

I don't want to discourage you Fido but if you are having issues at this point then it might be beyond your skill level. Depending on where you mount the control box a custom bracket of some sort is a real possibility. Also you may need to alter the length of the cables supplied to get a good fit, not a hard thing with the right tools and experience, but if cutting a bolt down is a challenge then its only going to get harder for you.

Having said all that, if you persist and get there the sense of acheivement will be great, its also good practice in case anything ever goes wrong in the bush, you will learn things doing this job that you never realised you didn't know!

Cheers Andrew

[mjrandom Out of control poster! Find all posts View Profile Close mjrandom]

Everyone has to start somewhere. Pass on the winch control box though, look through the build threads and see what other people have done.

[fido666 Banned Find all posts View Profile Close fido666]

not a hard thing with the right tools and experience, but if cutting a bolt down is a challenge then its only going to get harder for you.

It's not so much the challenge as the fear of wrecking anything. I was all set to have a go but hubby cracked it and that was that.

its also good practice in case anything ever goes wrong in the bush, you will learn things doing this job that you never realised you didn't know!

I've already learned lots doing this job, grill removal and bash plate removal for starters. I just don't think hubby could cope with pulling everything apart a 3rd time only to hit another hurdle, he doesn't have my patience.

Everyone has to start somewhere.

Thanks, if this were a computer build I'd be all set.

[mjrandom Out of control poster! Find all posts View Profile Close mjrandom]

Take it easy, don't rush and for God's sake don't put your fingers anywhere you wouldn't put something else!

I learnt by doing as my old man was one who would look at something then call a mechanic or fitter.

It helps being a mechanical engineer too.

[AJ120 Out of control poster! Find all posts View Profile Close AJ120]

Thanks, if this were a computer build I'd be all set.

If I did a computer build I would have cracked the $%*TS and smashed the stupid computer with a hammer and gone back down to my shed and used tools that I understand.

Tell hubby it will be third time lucky Alternativly head to the upcoming Vic tech day, a few guys with a bit of guidance each time you hit a problem will make all the difference.

Cheers Andrew

[fido666 Banned Find all posts View Profile Close fido666]

It helps being a mechanical engineer too.

There is that :-)

If I did a computer build I would have cracked the $%*TS and smashed the stupid computer with a hammer and gone back down to my shed and used tools that I understand.

My PC builds are a thing of beauty Andrew, and I have built too many to count.

Tell hubby it will be third time lucky Alternativly head to the upcoming Vic tech day, a few guys with a bit of guidance each time you hit a problem will make all the difference.

Yes I know about the tech day and have mentioned I have a winch that needs installing in that thread. I'm just a little impatient to get this finished, have had the winch since before Christmas.

[fido666 Banned Find all posts View Profile Close fido666]

Do Bunnings sell high tensile bolts? For the sake of a few $$ I'd rather buy new bolts than frig around with a hacksaw or angle grinder (both of which I'd probably have to but the appropriate blade/disc for).

Oh and just to prove I'm not totally mechanically inept here's a couple of pics of one of my more recent PC builds :-



Yes I know that's not a car but open up your PC sometime and see if it's that tidy LOL.