P1000 Superwinch Terra 45 Install with KFI Mount

[ToddACimer]

I bought a 4500 lbs Terra45 Superwinch and figured I would post up a few photos of the KFI mount and general installation. I chose the KFI mount because it mounts to the frame at both lower bumper mounts and at the front differential. I do not really like the EMP mount with the cheesy u-bolts or that it is bolted to the bumper rather than the frame

Here's the electrical under the hood. I wanted everything tucked under the hood and off to the side so I didn't loose any storage space or a future second battery location. Both the positive and negative cables to the battery were cut significantly shorter than the original kit cables

Here's the winch cables routed down the left side of the radiator and under the shroud

Here's the winch mounted on the KFI mount and the winch cables cut to length at the winch

Since the winch kit I bought came with steel cable and I switched to synthetic, I had a temporary roller fairlead installed until I bought a hawse. I didn't actually use the winch with the roller. I also didn't like the steep angle of the cable to the winch fairlead cut out in the bumper

Again, steep angle up above the top of the drum just to get to the fairlead cut out

Here's my thought of where the winch cable should have come out.

In order to route the cable through this location a few holes were needed in the stock front bumper

Here's the fairlead and the adaptor bracket I fabricated placed on the bumper

Here's the bumper mounted back up with the hawse in place

In order to do this mod, you will need the stock Terra45 mount inorder to attach the fairlead and bumper back to the frame. I alsu used the Terra45 bolt holes to transfer punch the hole pattern onto the back side of the bumper

Here's the cable routed through the cut out and quick edge installed around the cut out

Here's the fairlead bolted in place. I tightened up all the bumper bolts before installing the fairlead. I then tightened the bolts on the back side of winch mount. Lastly I tightened the jam nuts. This allows the bolts to put the bumper in compression and to make the structure more rigid

The final product, a straight line pull off the winch drum and a solid fairlead mount

Here's a side profile shot of the bumper after installation

 

[AKRider]

Nice work!

 

[ToddACimer]

With my winch fairlead relocated, my next task was adding a tow point for recovery and hooking my winch cable when using a snatch block. I made a 1/4" plate to mount behind the stock fairlead hole with a 12k weld on D-ring. End result turned out pretty good with spray on bedliner.

A little bit of cardboard aided design (CAD?) for hole layout and initial dimensions


Here's the hook plate with the 12k D-ring welded on

Parts ready for fit up. Bolt and washer, 3/16" spacer to allow the tow point to sit flush behind the fairlead cutout, washer and lock nut on the back side

Mounted up and winch hooked

Painted with Rustoleum bedliner

 

[Manwell]

Nice job and thanks for sharing!

 

[joeymt33]

Good idea!


Signature:

QUOTE by Sharp, Where's Don? He's probably spray painting stuff lmfao!

 

[GlockMeister]

I added a recovery point in that same place. Used some leftover half inch flat stock then added a shackle.

 

[ToddACimer]

I added a recovery point in that same place. Used some leftover half inch flat stock then added a shackle.

Do you have a winch?

 

[GlockMeister]

Negative..but on my list to add

 

[lrandy129]

Nice work and nice write-up, thanks. On a related note - does the Honda mount place the winch that low in the bumper or is it just the KFI?

 

[ToddACimer]

Nice work and nice write-up, thanks. On a related note - does the Honda mount place the winch that low in the bumper or is it just the KFI?

I have not seen the Honda mount installed in person. For me the price was a big turn off. I also wasn't a fan of the EMP mount with the winch upside down and most of the bolts going into the bumper rather than the frame.

 

[lrandy129]

I'm with you - would rather tie to the frame than the bumper. Looking at another thread, it sounds like the OEM setup has a harsh angle as well. Believe you nailed it with this install.

 

[ToddACimer]

I'm with you - would rather tie to the frame than the bumper. Looking at another thread, it sounds like the OEM setup has a harsh angle as well. Believe you nailed it with this install.

Thanks. I'm glad to have a secure mount for the winch, a good straight line pull angle and a sturdy tow point for use with a snatch block. Hopefully I'm not stuck too often to need them. I'm a little leary about the low speed clutch engagement and wheel slip and having a good recovery method should save clutches

 

[Corona1]

I like what you did there, nice work.
I went with the EMP mount to eliminate the steep angle, and to be honest not not very impressed with the mount.


Sent from my iPhone using Tapatalk

 

[GTKing]

I bought a 4500 lbs Terra45 Superwinch and figured I would post up a few photos of the KFI mount and general installation. I chose the KFI mount because it mounts to the frame at both lower bumper mounts and at the front differential. I do not really like the EMP mount with the cheesy u-bolts or that it is bolted to the bumper rather than the frame

Here's the electrical under the hood. I wanted everything tucked under the hood and off to the side so I didn't loose any storage space or a future second battery location. Both the positive and negative cables to the battery were cut significantly shorter than the original kit cables
View attachment 26949
Here's the winch cables routed down the left side of the radiator and under the shroud
View attachment 26950
Here's the winch mounted on the KFI mount and the winch cables cut to length at the winch
View attachment 26951
Since the winch kit I bought came with steel cable and I switched to synthetic, I had a temporary roller fairlead installed until I bought a hawse. I didn't actually use the winch with the roller. I also didn't like the steep angle of the cable to the winch fairlead cut out in the bumper
View attachment 26952
Again, steep angle up above the top of the drum just to get to the fairlead cut out
View attachment 26953
Here's my thought of where the winch cable should have come out.
View attachment 26954
In order to route the cable through this location a few holes were needed in the stock front bumper
View attachment 26955
Here's the fairlead and the adaptor bracket I fabricated placed on the bumper
View attachment 26956
Here's the bumper mounted back up with the hawse in place
View attachment 26957
In order to do this mod, you will need the stock Terra45 mount inorder to attach the fairlead and bumper back to the frame. I alsu used the Terra45 bolt holes to transfer punch the hole pattern onto the back side of the bumper
View attachment 26958
Here's the cable routed through the cut out and quick edge installed around the cut out
View attachment 26959
Here's the fairlead bolted in place. I tightened up all the bumper bolts before installing the fairlead. I then tightened the bolts on the back side of winch mount. Lastly I tightened the jam nuts. This allows the bolts to put the bumper in compression and to make the structure more rigid
View attachment 26960
The final product, a straight line pull off the winch drum and a solid fairlead mount
View attachment 26961
Here's a side profile shot of the bumper after installation
View attachment 26962

Great job with this mod. I have the same winch and want to do the same thing to my new P1000/5D. I'm curious about the adapter you fabricated for the hawse. What's it made of and how did you make it?

 

[ToddACimer]

Great job with this mod. I have the same winch and want to do the same thing to my new P1000/5D. I'm curious about the adapter you fabricated for the hawse. What's it made of and how did you make it?

I use 1"x1" or 1-1/4"x1-1/4" angle. I don't recall the actual size but it is the same height as the fairlead. Since the fairlead is bolted through the bumper and back to the Superwinch fairlead mount under the winch, the bolts hold the angle flush to the bumper and the fairlead at the right angle.

 

[GTKing]

I us


I use 1"x1" or 1-1/4"x1-1/4" angle. I don't recall the actual size but it is the same height as the fairlead. Since the fairlead is bolted through the bumper and back to the Superwinch fairlead mount under the winch, the bolts hold the angle flush to the bumper and the fairlead at the right angle.

Ok, I see. So I assume you just cut material out of the angle to make clearance for the rope and then drilled two holes in it for the bolts?

 

[ToddACimer]

Ok, I see. So I assume you just cut material out of the angle to make clearance for the rope and then drilled two holes in it for the bolts?

Yes the cut out was the size of the radiused portion of the fairlead so the rope won't touch it

 

[Joflu]

With my winch fairlead relocated, my next task was adding a tow point for recovery and hooking my winch cable when using a snatch block. I made a 1/4" plate to mount behind the stock fairlead hole with a 12k weld on D-ring. End result turned out pretty good with spray on bedliner.

A little bit of cardboard aided design (CAD?) for hole layout and initial dimensions

View attachment 36923
Here's the hook plate with the 12k D-ring welded on
View attachment 36924
Parts ready for fit up. Bolt and washer, 3/16" spacer to allow the tow point to sit flush behind the fairlead cutout, washer and lock nut on the back side
View attachment 36925
Mounted up and winch hooked
View attachment 36926
Painted with Rustoleum bedliner
View attachment 36927

I bought a 4500 lbs Terra45 Superwinch and figured I would post up a few photos of the KFI mount and general installation. I chose the KFI mount because it mounts to the frame at both lower bumper mounts and at the front differential. I do not really like the EMP mount with the cheesy u-bolts or that it is bolted to the bumper rather than the frame

Here's the electrical under the hood. I wanted everything tucked under the hood and off to the side so I didn't loose any storage space or a future second battery location. Both the positive and negative cables to the battery were cut significantly shorter than the original kit cables
View attachment 26949
Here's the winch cables routed down the left side of the radiator and under the shroud
View attachment 26950
Here's the winch mounted on the KFI mount and the winch cables cut to length at the winch
View attachment 26951
Since the winch kit I bought came with steel cable and I switched to synthetic, I had a temporary roller fairlead installed until I bought a hawse. I didn't actually use the winch with the roller. I also didn't like the steep angle of the cable to the winch fairlead cut out in the bumper
View attachment 26952
Again, steep angle up above the top of the drum just to get to the fairlead cut out
View attachment 26953
Here's my thought of where the winch cable should have come out.
View attachment 26954
In order to route the cable through this location a few holes were needed in the stock front bumper
View attachment 26955
Here's the fairlead and the adaptor bracket I fabricated placed on the bumper
View attachment 26956
Here's the bumper mounted back up with the hawse in place
View attachment 26957
In order to do this mod, you will need the stock Terra45 mount inorder to attach the fairlead and bumper back to the frame. I alsu used the Terra45 bolt holes to transfer punch the hole pattern onto the back side of the bumper
View attachment 26958
Here's the cable routed through the cut out and quick edge installed around the cut out
View attachment 26959
Here's the fairlead bolted in place. I tightened up all the bumper bolts before installing the fairlead. I then tightened the bolts on the back side of winch mount. Lastly I tightened the jam nuts. This allows the bolts to put the bumper in compression and to make the structure more rigid
View attachment 26960
The final product, a straight line pull off the winch drum and a solid fairlead mount
View attachment 26961
Here's a side profile shot of the bumper after installation
View attachment 26962

Did you encounter flexing in your bracket when pulling with the winch? I installed a Superwinch 4500 with a KFI 101285 mount. I find it’s flexing quite a bit.

 

[MTLuckyDan]

So for guys that plow...is it better to have the rope or cable coming out in the stock location regardless of angle? Thinking a low location like in this thread would not be good for lifting plow.

Sent from my P00I using Tapatalk

 

[ToddACimer]

So for guys that plow...is it better to have the rope or cable coming out in the stock location regardless of angle? Thinking a low location like in this thread would not be good for lifting plow.

Sent from my P00I using Tapatalk

I think the mount location is ok for a plow but a winch strap should be used instead of a rope or cable

Did you encounter flexing in your bracket when pulling with the winch? I installed a Superwinch 4500 with a KFI 101285 mount. I find it’s flexing quite a bit.

With most manufactured parts the holes are oversized or slotted. This mount is no different. Rather than rely on the shear of the bolt clamp load it's a good idea to preload the mount before final torque of the fasteners so the bolts are in shear rather than the clamp load of the bolts. If you mount the winch plate loose in the 4 bolts it probably will shift during the first full load pull.