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iSurfvilano

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About to be right there with you.

I just picked up a Warn Zeon 12 to replace my TJM 9,000 pounder.

Now the joy of pulling the bumper off and drilling the mounting points out for some grade 8 hardware.

Trying a different tack with this one. I went with the steel cable instead of synthetic. It is 18 pounds heavier, but after close examination of the synthetic on the TJM, I wasn't happy with how it looked after several years in the elements. That is one issue with all of these bumpers. There is not a easy way to run a cover to keep the sun and wet off of the synthetic. I figured with the steel cable that I could at least hose it down with oil from time to time. Time will tell, I guess.

I was sorely tempted to go with the **** bang platinum, but I will admit to being a little scared of the automatic clutch. If it is going to die on anybody, it would undoubtedly be me.

Wish me luck.
Good luck with the the grade 8 hardware! I think that should be standard when installing. It's definitely a little bit of a PITA getting to the lock nuts, but it's doable and worth it. I was able to snuggly fit the neoprene cover over my 12k. Also, you'll have to trim up your grill a bit to get that 12k to fit. Best of luck!!!
00100lrPORTRAIT_00100_BURST20200201071053043_COVER.jpg
 

avslash

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Good luck with the the grade 8 hardware! I think that should be standard when installing. It's definitely a little bit of a PITA getting to the lock nuts, but it's doable and worth it. I was able to snuggly fit the neoprene cover over my 12k. Also, you'll have to trim up your grill a bit to get that 12k to fit. Best of luck!!!View attachment 10588

On replacing the mount plate hardware, I'm assuming from the factory it is the standard welded in place nuts on the back side of the frame holes?

What I am planning on doing is just drilling them out. Most reports I have read online say that they tend to pop out when drilling them, but would love to hear details on your experience.

Once they are out, I'm planning on replacing them with a washer, lock washer, and nut. 1/2" size is the working plan right now.

Any pics of how you had to trim the grill?
 

avslash

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Well, that was a hell of a lot easier than I expected.

Bumper shell is off and lying in the backyard and old winch is out.

I was hoping against hope the winch plate was properly mounted by the shop that did the original install years ago, but no such luck. unfortunately, I didn't have a place to do my own work back then and I wasn't smart enough to insist that they do it the right way. So figuring that out ,s and the re running and neatening up some wiring the shop left is the next challenge.

I know nothing about the other bumpers mentioned in this thread, but having taken it off myself now the Tactical Rovers design is fantastic for maintenance. Literally 4 bolts, unclip your fog lights, unclip your front valve block and remove it. It was light enough that I didn't even need a helper.

ETA:. Other thoughts for weld nut removal as I'm getting tuned up for the Super Bowl.

Socket and long-assed breaker bar? Air hammer and break them off?

Put a torch on them to soften them up before attacking them?

Any thoughts?
 
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iSurfvilano

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Well, that was a hell of a lot easier than I expected.

Bumper shell is off and lying in the backyard and old winch is out.

I was hoping against hope the winch plate was properly mounted by the shop that did the original install years ago, but no such luck. unfortunately, I didn't have a place to do my own work back then and I wasn't smart enough to insist that they do it the right way. So figuring that out ,s and the re running and neatening up some wiring the shop left is the next challenge.

I know nothing about the other bumpers mentioned in this thread, but having taken it off myself now the Tactical Rovers design is fantastic for maintenance. Literally 4 bolts, unclip your fog lights, unclip your front valve block and remove it. It was light enough that I didn't even need a helper.

ETA:. Other thoughts for weld nut removal as I'm getting tuned up for the Super Bowl.

Socket and long-assed breaker bar? Air hammer and break them off?

Put a torch on them to soften them up before attacking them?

Any thoughts?
I just drilled them out...they pop off eventually
MVIMG_20191219_155150.jpg
:
 

iSurfvilano

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Once I drilled all 8 out, I sanded everything down and applied a few coats of POR15 on it prior to mounting the winch plate. Figured might as well to give it max protection...and @avslash , that will be the easiest part of this..finding grade 8 washers that fit behind there was tough for me locally... Tightening the lock nuts is really tough... Tight fit:
MVIMG_20191219_192855.jpg
 

iSurfvilano

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@iSurfvilano

What size bit did you use? Looks like 3/8 maybe?
I used 1/2" bolts so used a 1/2" bit, but it may be wise to go smaller first to get that weld out...I didn't though. Be sure you have a steady hand, the drill is going to want to pull to the right and that poses a risk of widening the hole. It worked out perfectly for me but I was worried that I would have to keep adjusting the holes to get the plate to fit.
 

iSurfvilano

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Any pics of how you had to trim the grill?
This is the only pic I have at the moment but can take more when I get home. Cutting it like this will get the tightest fit...I could've trimmed more to make installation/removal easier... But this is the minimum.
Screenshot_20200203-112240.png
 

avslash

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Thanks for the info and pictures.

I drilled one out with a 1/2" bit last night, but then decided I better hit pause as I was concerned I might be making too big of a hole. Put a call in to Tactical Rovers for their advice on size, but haven't heard back yet. I didn't have any trouble drilling it out. It popped right off as you said.

The POR 15 is a good idea. It's available locally, so I will pick some up today.

It is tight behind there, but I believe I can get a wrench on each of them to hold them while I torque from the front. At least on the passenger side I was messing with yesterday.

I'm going to run by the local Fastenal today and see what they have available in grade 8 hardware.

I'm debating cutting the grill or relocating the control pack of the winch to under the hood if that would prevent having to cut the grill. I'll do a test fit after I get the mount plate hardware sorted and finalized.

Thanks again for the info.
 

mbw

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Did you wire the fogs through the firewall or did you utilize the warn zeon connection point along with the winch remote? Thinking about getting a set of fogs next...

I used the existing fog light connectors that were already in the bumper.. same connectors just plug in. Super easy.

The zeon platinum accessory light connection is USELESS. They have a little wire that connects to the high beams, but it isn't so you can turn the lights on with your high beams at all.. its for a stupid EU safety law that shuts the lights OFF if you put your high beams on. Its backwards and stupid. Major missed opportunity there. I had to install my own relays to the battery to turn on my ARB lights with my high beams. The winch power accessory ports are really worthless.
 

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