Winch install: Project Overkill

[YBABRAT]

Winch is now installed but cable ordering and installation needs to be completed.

Installed the green cable for motor chassis ground, as it was no longer needed for remote placement of the contacter controller assembly. It is hidden once grill is installed. Remote placement makes things a little tighter looking fit without much effort in routing cables.

Here is the gap and view of how the motor studs are easy to work with in cable routing. You will need to remove grill, which will make all the effort in doing so small potatoes.

The grey nub is an electrical silicone isolator. I used it for future ground connections. Much easier to tap off the motor stud than to look elsewhere for ground without lifting hood.

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[YBABRAT]

Updating cable info as to why I am ordering custom cables.

The WARN cables are 3AWG and I want 2AWG at the minimum to drive the winch.

Looks like I'll use two 24" lengths of 2AWG from contacter to winch motor.

Current path will be 48" total.

Comparing that against the WARN 3AWG power cables would be 2 x 68" with a total current path of 136".

Whoa!

The length in its self would be restrictive with 2AWG, but 3AWG is going to show current restriction much easier.

IMO, WARN tried to make a winch installation kit for the masses and under sized their power feed cables. What winch company hasn't for cost cutting?

Any way, short current paths are key to providing winch power needs. There has not been many electronic devices that have a long life being underpowered.

Underpowered is as detrimental as overpowering electrical needs. Stress either way is no good.

 

[YBABRAT]

It's been some time... warm enough to install $70.00 worth of custom cables.

Look ma no ground cable to battery!

Yep only two red switched power cables from from the hidden WARN winch contactor controller. Had to notch out the grill facia (Widen the notch for bumper to frame extension) , more towards center for dual ground cables to winch motor.

The two 2 awg cables run under bottom radiator support and up along the side near the A/C compressor.

²

I made it a tight fit so everything is snug.

I tied things at the inner fender... the zip straps will be removed and installed from under the bracket in which they are shown mounted to. The factory air box still can be installed but not bolted down do to 1/2" gap from the cable.

I used up all the factory winch cables for other things that did not require above 300A.

Will need to obtain a ground cable to attach to my remote WARN winch controller at the frame. Also need to install my 100' synthetic rope.

Note I doubled the ground capability from the battery to frame with one of the reperposed aux battery cables.

 

[YBABRAT]

Here is my revised main power and secondary ground installation to fit factory and aftermarket air box. A wee bit more snug fit, but air box bolts in just as easy.

Need to obtain a 19" 2 awg ground cable to complete the installation.

Minor things to secure the WARN controller... a few 12" zip ties and a custom bracket to mount the 5 pin controller for a hard wired backup option, if wireless remote fails or my phone drops and breaks. My phone can control with the blue tooth addon for EVO winches.

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