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Old 01-29-2012, 10:41 AM   #1
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Warn Fairlead Cover Modification

I'm looking for a way to install a Warn Fairlead cover with a Viking Offroad safety thimble snugged up against the fairlead rollers. I was thinking I could notch out the center of the fairlead cover so the leading edge of the thimble pokes through the front of the fairlead cover.

Has anyone else done this? Or come up with a way to stop water from getting into the winch box through the fairlead?

Pictures of what I'm working with

I didn't like having this much synthetic line exposed to the elements with the winch line mounted this way


Front shot of van with safety thimble snugged up in the center of the fairlead


Picture of Warn Fairlead Cover


Top view looking down at the amount of safety thimble exposed in front of the plane of the rollers



And yes, I know I need some lights to fill the holes in the bumper.
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Gnarvan 1992 E350 Clubwagon
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Old 01-29-2012, 02:38 PM   #2
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Re: Warn Fairlead Cover Modification

This is the solution I came up with. I cut a vertical slot in the fairlead cover. Going vertical allowed me to mount a shackle on the safety thimble. The shackle secures the fairlead cover to the bumper. I put the other two Van Beest shackles on just for the picture. I wouldn't want to drive it around town like that. Not only would they chip the powder coat on the bumper they would disappear in a hurry. I'll probably pull the 3/4" Van Beest shackle off and put a cheaper one on.

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Old 01-29-2012, 11:42 PM   #3
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Re: Warn Fairlead Cover Modification

What is the part number of that Fairlead cover? They seem to make a lot of different types....
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Old 01-30-2012, 11:30 AM   #4
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Re: Warn Fairlead Cover Modification

I've had my shackles riding on my bumper for the last 3 years. Still there....
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Old 01-30-2012, 03:12 PM   #5
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Re: Warn Fairlead Cover Modification

Quote:
Originally Posted by ANZAC
What is the part number of that Fairlead cover? They seem to make a lot of different types....
I bought both the fairlead and the fairlead cover used from Kenny at Aluminess. I don't have part numbers for either one. Superwinch supplies a hawse fairlead with their synthetic rope winches. I wanted a roller fairlead so I could put a cover on it for protection from road grime. Kenny had the used one laying around so he made me a deal on it. He also sent it to the powder coater so it would match the custom color of the bumper.

I'll check the cover for part numbers when I get home tue morning and let you know
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Old 01-30-2012, 03:23 PM   #6
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Re: Warn Fairlead Cover Modification

Quote:
Originally Posted by carringb
I've had my shackles riding on my bumper for the last 3 years. Still there....
My van spends a lot of time sitting unattended at the takeout on the Wind. Last year someone stabbed one of our groups cat tubes while we were running shuttle. Ever since then I've had a bad feeling about leaving anything down at the end of that dirt road that could be easily stolen. There are quite a few wheelers that play around down there. A quality shackle like the 7/8" Van Beest would be a temping prize for someone with low moral standards and few beverages in them.
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Old 01-31-2012, 10:45 AM   #7
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Re: Warn Fairlead Cover Modification

Quote:
Originally Posted by ANZAC
What is the part number of that Fairlead cover? They seem to make a lot of different types....
I took a look at the fairlead cover this monring and couldn't see any part numbers. This cover does look different than most of the Warn fairlead covers I found when I googled it.

This looks very close to the cover I have
http://www.4wheelparts.com/Winches-and- ... n=WAR25580

Here are some additional pictures of the notched cover.

Front of notched cover


Back of notched cover
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Old 01-31-2012, 12:26 PM   #8
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Re: Warn Fairlead Cover Modification

I called Warn. They didn't seem very certain, but they recommended the 60390 instead.

Again, they did not seem very certain at all, they were very focused on "what bumper is it mounted to", and my point was "dude, it just clips onto the rollers".
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Old 01-31-2012, 12:56 PM   #9
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Re: Warn Fairlead Cover Modification

All bumpers are not created equal.

There are indents cut into the side of the cover I have that help it snug up against the Aluminess bumper. The bottom of the cover actually tucks up under the bottom edge of the bumper. If the bottom edge of the bumper wasn't in the proper spot the gizmos that hook to the rollers wouldn't be in the proper position to pop in.

When I was googleing I noticed a lot of their covers don't have the cut out sides.
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