Well I know I started this project over a year ago (finished this summer) but I figured it was worth posting anyway. I wanted to fit a Warn low profile M-8000 winch BEHIND the front crossmember with little to no mods to it. Turns out the M6000, M8000 and XD9000 all have the same overall dimensions so any could be used. I had an old M6000 laying around so I pulled the cable off and started seeing how it was going to fit...

Here's what I started with once the bumper was removed.
http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_4012-800.jpg

Close up...
http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_4013-800.jpg

My custom bumper. Up till now it was just bolted through the front crossmember by 8 bolts. I wanted to integrate this into a steering box plate and passengers side plate to get more tie in points. The center section on the back side is a piece of C channel with the rest of the bumper being 2x6 tube.
http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_4020-800.jpg

Here's how tight it is...
http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_4016-800.jpg

From the bottom...
http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_4017-800.jpg

I've torqued the motor up pretty good and haven't gotten the crank or fan to hit anything so I should haven't any problems. I'm running MORE motor mounts so the engine doesn't move around much.

I had a shop shear out a piece of 3/16" plate and bent up the ends so that it fit between the front frame tabs on the crossmember.
http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_7183-800.jpg

Drilled a couple holes that line up with the C-rok steering box plate and the crossmember.
http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_7185-800.jpg

http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_7186-800.jpg

http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_7188-800.jpg

Put the winch where I wanted it and marked the holes.
http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_7284-800.jpg

Here's the end caps for the channel. They ended up getting 2 holes drilled and tap'd in each endcap.
http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_7184-800.jpg

And here's the copy of the steering box plate that goes on the passengers side. Turns out the plate was hardened so I had to torch instead of drill (which I didn't like) but it worked.
http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_7182-800.jpg

I need to see if I have a pict of the back of the bumper with all the holes cut in it. I had to cut 4 large (1.5") holes in the back of the bumper that clear the winch bolt heads. Assembly consisted of running the 4 winch bolts through the reinforcement plate, through the jeep crossmember, and into the winch. Then the bumper went on with the 1/2" bolts coming from behind the crossmember, through the reinforcement plate and then got threaded into the back of the bumper. Then the 2 bolts per side held the frame plates to the bumper to the frame. It was pretty tight but it all fit, just took a little longer to put together.

Here's where the fairlead ended up. It's about 1.5" off center due to the steering box. I'm running the durango box so I don't know if it would be closer to center with a stocker or not.

http://www.rocketcityrockcrawlers.com/forum/uploads/scoutman/2008-05-11_220934_IMG_8090-800.jpg

Got the switches mounted in the dash...
http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_8096-800.jpg





I'll have to go find some more picts that are on my home puter. They'll show how much I had to cut off the fan shroud, where the solenoids went, etc.

Somewhat finished. I didn't have the synthetic line on it in this pict but you get the idea. I welded a couple trick tabs on the front for some lighting. I've got an Aluminum fairlead that should be back from being black annodized sometime this week. :smokin:

http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_8166-800.jpg

Rock lights tuck up nice and tight.
http://www.rocketcityrockcrawlers.com/memberstuff/cash/blue%20xj/hiddenwinch/IMG_8168-800.jpg

how hard is it to flip the lever with it up there?

how hard is it to flip the lever with it up there?

Not very, just make sure of where you're putting your hand. :eek:

Here's the picts of the cut fan shroud and all the parts.