Now that the holidays are behind me, I've had a chance to do a bit more work on it. I decided to maintain Warns original designed strength by rotating the free spool lever every other hole. Works out that 180* is not a strength option I'm willing to risk. Sadly that means cutting the beautiful hammer finished powder coated mount.
Free Spool adapter is nothing short of amazing...
The angle I chose...54 degrees, out the top of the bumper.
Located hole center using a straight edge and measured down half the diameter of the adapter. (D=30mm, R=15mm). Center punched and pilot drilled all the way through with a very small drill bit, same angle as the adapter. That is some tough steel. Hot rolled?
Followed the pilot hole with a 1/4" drill checking the angle. Wasn't easy getting it started but it finally went through. Then used a 3/4" hole saw to to bust through. Thanks Anak for the 1/4" round stock guide tip. Worked great. As you can see, alignment came out near perfect. But I tagged that adapter with the hole saw. :doh: Hope my hole saw is okay!!!
Made new power cables to extend the control box. Used 8 ton hydraulic hex crimper on tin coated copper lugs, and 2awg welding wire. Sealed in with adhesive shrink tube. Also labeled and clear adhesive shrink. Should last awhile. Made them 57" long. Control box will be mounted where the radiator overflow is now. Cables are slightly too long. Better too long than too short. Anyway, covered them in anti abrasion. Need just a little more in the second pic. Secured with a couple of straps.
Bottom of blue tape is the top surface of my bumper. Looks like the the opening will clear perfectly without getting into the grill or be too far forward. I have the DirtBound Mohave DIY. Originally built it with the receiver hitch. Cut the receiver out and notched for the fair lead opening. Welded in the slug I originally cut out for the receiver hitch. I don't like it. My front bumper now looks like crap. It warped making it difficult to get back on and now has a inward bow. Yuck! I'm going to attempt to salvage the original looks which will hide the winch opening. No pictures of the bumper, it got dark. Really!