Winch Upgrade

Since I bought my car hauler many years ago, I've just been using a cheap $50 Harbor Freight ATV winch with a 2500 lb rating. It worked surprisingly well, for the most part. I used a snatch block when I needed more oomph.

But I did damage a couple of the winches since I wasn't doing a straight pull.

Original ATV Winch with damaged drum

Tool Box

I installed the tool box right after I bought the trailer in 2016. It's perfect storage for my weight distribution hitch, tie down straps, trailer spares, etc. This type of job box is weather sealed and also has very good security.

But it took up a LOT of space on the deck. I decided that the toolbox had to be part of the winch solution. I wanted to get a straight pull on the winch, and also free up more of the trailer deck.

Original Toolbox Location

Obvious solution

Move the toolbox towards the tongue
Move the winch into the toolbox for security and weather protection

Cutting

I started by cutting the front rail and mocking up some new rails to support the toolbox

I also cut the two feet off of the toolbox (no picture), and shortened an old winch plate to fit inside the toolbox. The winch plate was a freebie that I've had around for several years.

Since nothing is ever easy, the old winch plate was sized for an 11" roller fairlead. My new winch had a 10" roller fairlead 😡. So I welded it smaller and drilled the holes for 10" to fit.

I also welded some 3/8" spacers underneath the winch plate for clearance for the winch retaining bolts (no picture)

After many test fits, road blocks, cursing, hernias, etc, we ended up with two rails welded onto the frame.

For strength, I used six 1/2" bolts - four through the winch plate and two just through the toolbox. The rails have welded nuts for securing the winch plate and tool box.

There is also a welded gusset plate on each rail that you can't see in the pictures.

The rails extend out beyond the tool box, so the large hole at the end of each rail can be used as a tie down point.

The new winch is a Harbor Freight 9500 lb. It only cost $250 a few months ago with a good coupon.

Here's the internal layout. Mark gave me the Optima battery mount several years ago, and I finally got around to using it! Thanks, Mark!

The extra storage space will still fit a lot of the same items as before: the weight distribution hitch, ratchet straps, etc.

I added a 20w solar panel to keep the battery charged. And, of course, cut a hole for the winch cable.

I'm going to make some type of sealed box to cover the roller fairlead to keep rain and critters out of my tool box. (For now, I just removed the roller fairlead and put on a cover plate.)

Three main tasks remaining for 2024:

Weather seal for the roller fairlead
Finish the internal wiring, which will be pretty easy.
Stain the new wood

Trailer Jack

The old jack was top crank, which wouldn't be ideal for the new tool box location. It was also a little bent from where it had scraped a large dip at a gas station entrance.

I installed a new side crank jack that tucks up into the frame better - hopefully, no more scraping the ground!