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Old 10-30-2015, 09:42 AM
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Running Winch Wires around Grille?

I have a Superwinch TS9500 mounted on a Rock Hard winch plate (stock bumper). As of right now I have the wires running through the grille because the positive isn't long enough to run any other way. Plus I'm not exactly sure where everyone else runs them if they don't go through the grille. I've seen pics of people running them under the grille and then next to the radiator, or around the passenger side and then up into the engine bay (but there is a tiny area exposed inside the wheel well that way.
So my question has 2 parts:

1. Any advice on how to lengthen the lines? Not sure on the gauge of wire, and then how to connect the two?

2. Does anyone have any closeup pics of just HOW exactly you ran your wires if not through the grille. I plastidip mine and the prospect of unwiring the winch every time makes me shudder. It will already be a pain with the winch plate. I also plan on looming the wires to prevent any rubbing.

Thanks!

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Old 10-30-2015, 12:08 PM   #2
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I ran mine through the grill however I do recommend avoiding any rub areas, I loom mine and check periodically any rubbing. I have investigated several vehicle fires where the positive rubbed enough to start a fire. Happens more then most folks think especially when winches are installed. Also have seen several fires caused by rodents chewing on the wires here in Colorado where salt is used in some counties.

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Old 10-30-2015, 12:39 PM   #3
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Originally Posted by dirtleg View Post

1. Any advice on how to lengthen the lines? Not sure on the gauge of wire, and then how to connect the two?
You should be able to find the min wire gauge with a little online research. Rather than trying to cobble together some kind of splice, I would just replace it with a longer one. Depending on wire gauge required, you might be able to get a generic positive battery cable in the right length.

If you need to make one, you can buy most gauges of wire by the foot at lowes or home depot, then swedge a new fitting on the end with a hand swedger (like a giant set of wire crimpers) you can get the tool from the home depot tool rental program or maybe even the loaner dept. at auto zone, at least around here.

Note- if you add length to an electrical conductor, the wire typically needs to get bigger (smaller gauge number). There are plenty of reference guides that show how many amps and how many feet a given wire gauge can handle before going to a bigger size.
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Old 10-30-2015, 05:08 PM   #4
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It would have made it a whole lot easier if Warn had given about 8" more length!

Ended up having to run them across the top of the battery instead of around the edge.

Why do they insist of making them so short, I can't imagine if you had a truck they would even reach.
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Old 10-30-2015, 08:19 PM   #5
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It would have made it a whole lot easier if Warn had given about 8" more length!

Ended up having to run them across the top of the battery instead of around the edge.

Why do they insist of making them so short, I can't imagine if you had a truck they would even reach.
You have a Zeon and the lead is too short? Come on, Warn.
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Old 10-30-2015, 10:05 PM   #6
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I ran mine through the grill. Fortunately, if you need to pull the grill, you can just open up the solenoid cover and disconnect the leads there.
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Old 10-31-2015, 10:57 AM
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Ah yes...disconnecting them in the solenoid NEVER even crossed my mind! Now we'll see if it will slip passed the Rock Hard winch plate.
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Old 10-31-2015, 09:27 PM   #8
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I faced the same issue, so I went to the local 4x4 shop and they had 10ft cables for $20 each. I don't have closeups of the whole run but here is the start and just run it along the passenger fender. The wire is 1/0 guage, some welding shops have "welding wire" and you can buy it by the foot. Usually it's only in black. I was going to use red heat shrink for the pos lead. The end connectors will be either soldered or crimped on. I would prefer them to be crimped personally, the welding shop should be able to do that. But when I found the extended wire at the shop, I just went that way.

Here with the RH winch plate




With the new bumper it's the same
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Old 11-01-2015, 06:13 AM   #9
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I have my winch mounted in a Hard Rock bumper and relocated the solenoid to under the hood. I had to change all the cables out.

Winches usually use 4 gauge battery cable. You can order battery cable in 25 foot spools and crimp the lugs as mentioned earlier.

You can also order custom size cables from Marine Wiring, Boat Cable and Electrical Genuinedealz.com.

They are marine grade cable which is a tinned copper cable to help prevent corrosion in salt water environments. For those living in states that use salt as an ice fighting method, its the way to go. Marine cable also tends to be very flexible.

Be careful of using house grade wire (found in hardware stores) for automotive purposes. The wire is not always designed to deal with UV light, salt and the stranded cables typically have less strands, although thicker, making it less flexible and prone to breaking off at the lug in vehicles that move and flex.
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Old 11-01-2015, 08:24 AM   #10
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My Warn came with #2 gauge power and ground, 72 inches long. The positive cable has a loam around it to prevent chaffing. That length was plenty to get to the battery. I ran mine under the grill, up along the side of the radiator, through a small opening between the radiator and radiator support into the engine compartment, behind the power steering reservoir, and along side the battery. I zip tied it along the way. It's a close fit but nothing is stretched, binding, or rubbing. There is no exposure in the wheel well.

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