Big Red 250es winch mount

[Georgiabii]

Thought I'd start a new thread for this one... Now that the bike is running it's time to start outfitting it for me :naughty: And the first thing I think it needs is a self recovery option.

The factory front rack just isn't solid enough to mount a winch and honestly I don't want to lose the cargo space so I decided to go a bit different. I'd already planned on replacing the 80's headlight with some modern LED so it was an easy decision to dump the headlight. Then I found this huge box with the wiring plugs in it... That had to be changed to make some room.

http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160227_193455_zpscstgcr7z.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160227_193455_zpscstgcr7z.jpg.html)
This is what you will find if you open up the factory enclosure. A nest of wires and in my case dirt dobber nests. I think we can fix that!

http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160228_153346_zpsw2hhbtq1.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160228_153346_zpsw2hhbtq1.jpg.html)
This is the new electrical box. Smaller and fits in a tight area a bit better. Don't worry when I'm done it'll be firmly mounted to the front rack. It's also sealed against the elements better.


Now on to the winch. *disclaimer* I'm not a professional welder. *disclaimer*

I did not want to weld to the forks in any way so I decided to do a bolt on setup.

First Mock up.

http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160228_192739_zpsiwof24vn.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160228_192739_zpsiwof24vn.jpg.html)

Fits pretty decent and I think I can work with this. Notice that there is a set of U bolts holding the mount to the forks. When it's done there will be a total of 4 attachment points.


http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160228_170137_zps9hk0oacv.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160228_170137_zps9hk0oacv.jpg.html)
Middle of the welding. Just using a cheap 90 amp wire feed flux core so there is a bit of a mess.

http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160228_192642_zpsrytzkmcl.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160228_192642_zpsrytzkmcl.jpg.html)
Right side early mounting tack welded.
http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160228_192658_zpsx2m30ivj.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160228_192658_zpsx2m30ivj.jpg.html)
Left side early mounting tack welded.

http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160228_192628_zpsm5mvebna.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160228_192628_zpsm5mvebna.jpg.html)
Checking winch position and for clearance. Looking good so far. Winch is a cheap Badlands 2500 atv winch with an upgraded synthetic winch rope instead of the cable. I hate steel cables!

http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160228_170117_zpspcpajrjq.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160228_170117_zpspcpajrjq.jpg.html)
Winch mount plate just before I welded it to the frame. Yes my work bench is a disaster...

http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160228_235416_zpsja1ega7l.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160228_235416_zpsja1ega7l.jpg.html)
http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160228_235406_zpsi0nszjyn.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160228_235406_zpsi0nszjyn.jpg.html)
Winch control box. This winch uses a wireless key fob so it needs a controller. This is where it's going to mount. Cables will go directly to the battery along the frame with the other factory wiring.

http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160228_235116_zpsiuookhko.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160228_235116_zpsiuookhko.jpg.html)
http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160228_235056_zps65u7qtxh.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160228_235056_zps65u7qtxh.jpg.html)
http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160228_235049_zpser5bnpfe.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160228_235049_zpser5bnpfe.jpg.html)
http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160228_235044_zpskilgqjqi.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160228_235044_zpskilgqjqi.jpg.html)

Waiting on the paint to dry.

http://i18.photobucket.com/albums/b104/georgiab2/Big%20Red/20160228_192708_zpszxf2k5br.jpg (http://s18.photobucket.com/user/georgiab2/media/Big%20Red/20160228_192708_zpszxf2k5br.jpg.html)
This is how everything will mount up.


Thoughts? Idea's? Snarks?

[DohcBikes]

The u-bolts you used are rated for about 10 ft/lbs of torque before they snap. If you doubt this, borrow a torque wrench, buy an extra u-bolt of the same quality, and see how much it takes to snap it. If you are stuck enough to actually need a winch, i wouldnt trust those ubolts to hold it together.

One of the great things about three wheelers is the ability to pick them up when they get stuck. Can't remember a single time when I would have needed a winch to unstuck.

What a messy shop! To each their own, I guess.

[Georgiabii]

Interesting so your saying the bolts won't hold more than 10ftlbs?