Making A Warn Zeon Fit My New JK Pure Jeep Bumper!!! - Jeep Wrangler Forum
Jeep Wrangler Forum

Go Back   Jeep Wrangler Forum > JK Jeep Wrangler Forum > JK General Discussion Forum

Join Wrangler Forum Today


Reply
 
Thread Tools

Please support our sponsors and let them know you heard about them on WranglerForum.com
Old 12-29-2012, 06:50 PM   #1
Jeeper
 
dvdsjk's Avatar
 
Join Date: Nov 2011
Location: NePa
Posts: 586
Making A Warn Zeon Fit My New JK Pure Jeep Bumper!!!

Ok I bought the Warn Zeon a awhile back when I ordered the Pure Jeep bumper. So they finished the bumper and it arrived yesterday! Good right? Well I put it in the plate only to find thet the Zeon is a perfectly centered winch unlike most. Take it back? Hell no it looks too good there especially how it centered with the grille!! So this is what Im gonna do. First drill the plate to mount the winch feet. Second cut the hole for the fairlead so it will now be centered. Thirdly make it look fairly decent while doing this in my own little garage!! Heres the start:
First you could see how its really off the original cut:


First mark my cuts and holes to be drilled:


Second make template:


Third Drill and cut the new bumper!!



Set template in the center position:



Ok so now im going to mark the 3" flat stock I bought lowes. Im going to span the old fairlead hole and drill a new hole on the otherside to make it look even. This is where I ended up tonight.

dvdsjk is offline   Quote Quick Reply
Old 12-29-2012, 08:40 PM   #2
Jeeper
 
reade's Avatar
 
Join Date: Oct 2012
Posts: 371
Great work. I had to do some cutting and grinding to get my Zeon in the Rugged Ridge XHD bumper but nothing like that. Well, maybe it was kind of like that but I own a Bridgeport milling machine and I milled my bumper. To do this free hand deserves a hand.

reade is offline   Quote Quick Reply
Old 12-29-2012, 08:52 PM   #3
Jeeper
 
dvdsjk's Avatar
 
Join Date: Nov 2011
Location: NePa
Posts: 586
Quote:
Originally Posted by reade View Post
Great work. I had to do some cutting and grinding to get my Zeon in the Rugged Ridge XHD bumper but nothing like that. Well, maybe it was kind of like that but I own a Bridgeport milling machine and I milled my bumper. To do this free hand deserves a hand.
Thanks man!! Im an electrician and and do tons of hospital work. All our cutting is on the fly. We learn to improvise with a sawsall!!
dvdsjk is offline   Quote Quick Reply
Old 12-30-2012, 08:21 PM   #4
Jeeper
 
dvdsjk's Avatar
 
Join Date: Nov 2011
Location: NePa
Posts: 586
A little update. Plate is made! And started putting things together!

dvdsjk is offline   Quote Quick Reply
Old 12-30-2012, 10:48 PM   #5
Race Car Dave

WF Supporting Member
 
NFRs2000NYC's Avatar
 
Join Date: Nov 2011
Location: NYC
Posts: 6,927
I had to do a lot of cutting and grinding to make it work with my Rampage bumper, but it was worth the labor. Nice work!
NFRs2000NYC is offline   Quote Quick Reply
Old 01-01-2013, 08:30 PM   #6
Jeeper
 
dvdsjk's Avatar
 
Join Date: Nov 2011
Location: NePa
Posts: 586
Quote:
Originally Posted by NFRs2000NYC View Post
I had to do a lot of cutting and grinding to make it work with my Rampage bumper, but it was worth the labor. Nice work!
Thanks NFRs2000NYC !!

Pic of the dry fit.

dvdsjk is offline   Quote Quick Reply
Old 01-01-2013, 08:56 PM   #7
Jeeper
 
reade's Avatar
 
Join Date: Oct 2012
Posts: 371
This shows where I had to cut,



I'll say this, a machine is nice but they can't replace a man with the skill to do the job by hand, they only make the job easier. Congrats on being that man.
reade is offline   Quote Quick Reply
Old 01-01-2013, 09:10 PM   #8
Jeeper
 
dvdsjk's Avatar
 
Join Date: Nov 2011
Location: NePa
Posts: 586
Quote:
Originally Posted by reade View Post
This shows where I had to cut,



I'll say this, a machine is nice but they can't replace a man with the skill to do the job by hand, they only make the job easier. Congrats on being that man.
Thanks for the compliment reade!!
dvdsjk is offline   Quote Quick Reply
Old 01-01-2013, 09:13 PM   #9
Jeeper
 
reade's Avatar
 
Join Date: Oct 2012
Posts: 371
If you ever got around some machines you'd be dangerous.

That is a compliment by the way. I try to tell people all the time that want to be a machinist until they can do it without the machine they aren't ready to be a machinist.
reade is offline   Quote Quick Reply
Old 01-01-2013, 09:32 PM   #10
Jeeper
 
dvdsjk's Avatar
 
Join Date: Nov 2011
Location: NePa
Posts: 586
My Grandfather was a machinist many many many years ago. I almost tried that route before deciding that electricity would be my gig!!!
Oh I can paint too!! Ha!!
dvdsjk is offline   Quote Quick Reply
Old 01-01-2013, 09:52 PM   #11
Jeeper
 
reade's Avatar
 
Join Date: Oct 2012
Posts: 371
Fingernail polish goes on the other side.

I've been thinking about doing that little logo on mine too. Looks cool.
reade is offline   Quote Quick Reply
Old 01-02-2013, 05:48 PM   #12
A-14

WF Supporting Member
 
1Topp's Avatar
 
Join Date: Oct 2011
Location: BarkCamp Ga.
Posts: 1,410
Images: 72
__________________


A-14 Build
A-14 Profile
A-14 Pics
1Topp is offline   Quote Quick Reply
Old 01-02-2013, 07:44 PM   #13
Jeeper
 
dvdsjk's Avatar
 
Join Date: Nov 2011
Location: NePa
Posts: 586
Quote:
Originally Posted by reade View Post
Fingernail polish goes on the other side.

I've been thinking about doing that little logo on mine too. Looks cool.
The other side! Thats where I always mess up!!!
And the logo was easy. red paint, a tight rag wrapped around a finger, and a drop of acetone!!


Quote:
Originally Posted by 1Topp View Post
Thanks 1Topp! Shes getting there!!!
dvdsjk is offline   Quote Quick Reply
Old 02-12-2013, 09:38 PM   #14
Jeeper
 
dvdsjk's Avatar
 
Join Date: Nov 2011
Location: NePa
Posts: 586
May as well finish up this thread with a finished bumper pic! All powder coated !!
dvdsjk is offline   Quote Quick Reply
Old 02-12-2013, 09:41 PM   #15
Race Car Dave

WF Supporting Member
 
NFRs2000NYC's Avatar
 
Join Date: Nov 2011
Location: NYC
Posts: 6,927
Quote:
Originally Posted by dvdsjk View Post
May as well finish up this thread with a finished bumper pic! All powder coated !!
Why do you have a cover on your Zeon? It's sealed, and you can buy a rope cover. Seems odd to me.
NFRs2000NYC is offline   Quote Quick Reply
Old 02-12-2013, 10:01 PM   #16
Jeeper
 
dvdsjk's Avatar
 
Join Date: Nov 2011
Location: NePa
Posts: 586
Salt!!!! Destroys and corrodes everything here. All you would need is one chip from the aggregate (small stones) they use for ice on the roads and then hit the state roads salt and forget the finish not to mention the rope damage!
dvdsjk is offline   Quote Quick Reply
Old 02-12-2013, 10:04 PM   #17
Jeeper
 
dvdsjk's Avatar
 
Join Date: Nov 2011
Location: NePa
Posts: 586
Oh and the rope cover is a joke. A piece of plastic that just bareley covers the front but still leaves the back wide open!!
dvdsjk is offline   Quote Quick Reply
Old 02-12-2013, 10:14 PM   #18
Jeeper
 
dvdsjk's Avatar
 
Join Date: Nov 2011
Location: NePa
Posts: 586
I forgot to mention for you Zeon guys to check your screws on the gear side. Mine weren't tight from the factory and Warn gave me a new Winch!! I noticed a washer moving on the small screws. Called warn and they told me they wanted it back. Oh and this is what the salts doing to my new skids already!
dvdsjk is offline   Quote Quick Reply
Old 02-12-2013, 10:52 PM   #19
Race Car Dave

WF Supporting Member
 
NFRs2000NYC's Avatar
 
Join Date: Nov 2011
Location: NYC
Posts: 6,927
Quote:
Originally Posted by dvdsjk View Post
Oh and the rope cover is a joke. A piece of plastic that just bareley covers the front but still leaves the back wide open!!
Rope cover is for UV degradation. There is no sun coming in through the back.
NFRs2000NYC is offline   Quote Quick Reply
Old 02-13-2013, 12:44 AM   #20
Jeeper
 
Join Date: Mar 2011
Posts: 56
Quote:
Originally Posted by dvdsjk
May as well finish up this thread with a finished bumper pic! All powder coated !!
What cover did you use?
Jaysrubi is offline   Quote Quick Reply
Old 02-13-2013, 04:51 AM   #21
Jeeper
 
dvdsjk's Avatar
 
Join Date: Nov 2011
Location: NePa
Posts: 586
Quote:
Originally Posted by NFRs2000NYC View Post
Rope cover is for UV degradation. There is no sun coming in through the back.
Again its for the SALT! And actually , the back is exposed yo the sun when the sun is directly above it. When you become familiar with winches you will see what damage the sun does. I'll take pics of what it did to my Smittybilt including the wire coating damage ad yes in the BACK of the winch!

Quote:
Originally Posted by Jaysrubi View Post
What cover did you use?
I used the cover for the Warn 9000lb winch. Tight but works

dvdsjk is offline   Quote Quick Reply
Reply

Quick Reply
Message:
Options

Register Now

In order to be able to post messages on the Jeep Wrangler Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.
User Name:
If you do not want to register, fill this field only and the name will be used as user name for your post.
Password
Please enter a password for your user account. Note that passwords are case-sensitive.
Password:
Confirm Password:
Email Address
Please enter a valid email address for yourself.
Email Address:

Log-in

Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools

Posting Rules
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off



» Rates
Get low rates on auto insurance in Canada!

» Network Links
»Jeep Parts
» Featured Product

All times are GMT -5. The time now is 08:10 AM.



Jeep®, Wrangler, Liberty, Wagoneer, Cherokee, and Grand Cherokee are copyrighted and trademarked to Chrysler Motors LLC.
Wranglerforum.com is not in any way associated with the Chrysler Motors LLC