Warn 9.5ti in FZJ 80 stock bumper.

Warn 9.5ti in FZJ 80 stock bumper.

I don’t know why, but I like to try and fit winches into the stock bumper.  Here I will install a Warn Industries 9.5ti winch into my ’95 FZJ80 Land Cruiser.  A standard configuration winch would have been much easier to install, as the 9.5ti has the solenoids mounted inside the top cross brace.  This required extra clearance when figuring out how to position the winch.

To start with, I fabricated some frame horn extensions that the winch mounting plate will be attached.  I used the exhisting mounting holes and the stock extensions as the pattern.  I also used the stock extensions as the outside of the bracket and to fill in the front.

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Next, I made my winch plate from some 1/4X 4″ square tube.  I copied an old winch plate that I had modified for my FJ60 Winch Installation.  Due to the dimensions of the winch and the space between the frame rails, the plate is slightly asymmetric.

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After some careful measuring, I trimmed the lower valance to fit the top of the winch

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After welding the plate to the extensions, I trimmed the plate 4.5″ on each side, in the front so I didn’t have to trim too much of the bumper.  It’s hard to see, but there is a 45deg filler welded in.  I didn’t just want to trim the front of the plate like I had seen on some other installs, thinking the more structural support, the better.

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Installed in the front before installing the bumper.

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It isn’t centered in the bumper, but doesn’t look too bad.  It took several trim, fit, trim sequences before I got it right, without removing too much bumper.

You can’t see it in this picture, but I also trimmed the top of the bumper so the cord can be plugged in, the brake lever can be operated and to hopefully aid in cooling. There still needs to be a little trim added to the sharp edges, but it’s all buttoned up.

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