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Old 06-17-2011, 02:07 PM   #1
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Refurbished winch build

I was given a XD9000i WARN winch and after I ordered a OEM bumper winch plate I was dismayed to find that the winch was non functionable (see photo) so..... I inspected gear end and decided to spend the 450 to buy parts. I have totally broke it down, sandblasted (chrushed glass) and repainted housing in bed liner paint. Here is progress photos. Also repainted all new plate mount parts in same.

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Old 06-17-2011, 02:10 PM   #2
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Photos
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Old 06-17-2011, 03:39 PM   #3
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Nice project. Keep the updates coming.
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Old 06-17-2011, 05:06 PM   #4
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Sweet.

I like it when I see someone turn a possible junk yard donation into a great looking working device. It gives me incentive to try it myself going forward. I've been gearing up to do some similar stuff but haven't found any interesting victims of neglect yet.
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Old 06-18-2011, 06:53 PM   #5
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Installing Smitty winch mount plate to frame
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Old 06-19-2011, 02:44 PM   #6
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Top frame bolts were PITA, impossible to reach with fingers, finally use fishing line, feed thru bolt hole, wrapped inside of bolt threads, small piece of electrical tape, then pulled bolt up thru frame and into hole. Worked like a champ.

Here is a pic of everything but winch, still waiting for parts.

Note you do have to notch bothe the plastic bumper and metal bumper to fit over brackets.
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Old 06-19-2011, 02:51 PM   #7
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Quote:
Originally Posted by repauli1 View Post
Top frame bolts were PITA, impossible to reach with fingers, finally use fishing line, feed thru bolt hole, wrapped inside of bolt threads, small piece of electrical tape, then pulled bolt up thru frame and into hole. Worked like a champ.

Here is a pic of everything but winch, still waiting for parts.

Note you do have to notch bothe the plastic bumper and metal bumper to fit over brackets.
This is the main reason I got the Rough Country winch mount plate. It required no modification of the bumper or its cover.
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Old 06-19-2011, 03:08 PM   #8
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Originally Posted by jk'n

This is the main reason I got the Rough Country winch mount plate. It required no modification of the bumper or its cover.
Those OEM bumpers should be outlawed, I think a direct hit from a pheasant would taken out. I am getting a better bumper when I decide on exactly what I want.
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Old 06-19-2011, 03:13 PM   #9
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Those OEM bumpers should be outlawed, I think a direct hit from a pheasant would taken out. I am getting a better bumper when I decide on exactly what I want.
I agree. Eventually, I will upgrade the bumper. Other priorities right now. I have to be careful not to pull too much money out of family finances so, I went with the winch and OEM bumper mount for now.
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Old 06-21-2011, 08:00 AM   #10
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Excited, got my winch parts, now I can finish my project YEH!
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Old 06-21-2011, 10:12 PM   #11
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Here's all the new parts!
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Old 06-25-2011, 11:53 AM   #12
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Drum, honing out brake surface with a master cylinder hone from Napa, then sand, prime, paint with bed liner.
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Old 06-25-2011, 04:05 PM   #13
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Quote:
Originally Posted by repauli1 View Post
Top frame bolts were PITA, impossible to reach with fingers, finally use fishing line, feed thru bolt hole, wrapped inside of bolt threads, small piece of electrical tape, then pulled bolt up thru frame and into hole. Worked like a champ.

Here is a pic of everything but winch, still waiting for parts.

Note you do have to notch bothe the plastic bumper and metal bumper to fit over brackets.
good choice on the winch plate man. I got the same one and it's not easy by any means to install, but looks WAY better IMO over other brands. Much cleaner. once it's all done you can't see where you had to cut.
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Old 07-03-2011, 08:49 AM   #14
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Project winch complete and ready to pull!
Total cost 600 with mount plate.
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