I tackled the bumper from hell again today. The goal was to remove the bumper, spray a coat of matte black over it to hide the various chips from shipping, then install the new winch, remount the bumper, adjust it properly, and then fabricate a mesh guard for the intercooler radiator..
I worked on it for 6 hours and finally called it quits during the adjustment phase. I swear that bumper was designed by the Chinese to be as difficult as possible to work with. It seems like most of the nuts and bolts are positioned in such a way as to make reaching them with normal male hands is very difficult and you are likely to injure yourself.
I bought a winch that I saw some good reviews on; the Openroad Panther Series 3S 13,500lb winch. I was going to go with the Badlands Apex, but this had some cool features and was a bit more modular.
The first challenge was that the bumper did not have enough room for a normal winch...
I nearly stopped right there and scrapped the whole dang bumper and ordered a new one. But, I decided to try and move the relay box somewhere else. Because of the limited length of the cables, I had very few options. I did find a mounting spot that worked, and the relay is actually tucked up under the bumper more than the photo suggests, and my expanded metal guard will also be covering it...
I got everything mounted and was in the middle of trying to adjust the bumper when my socket slipped and gashed my right thumb on some metal. I was beat and just decided to finish it up tomorrow.
