OK, did some measurements on my 2014 Express yesterday.
A major hurdle is the cross member/bumber
There is very little info on the web of whats under the bumper cover on an Express. I can't speak for sports. I assume they are the same.
Bumpr cover removed.
Bumper absorber removed, showing the crossmember.
Cross member is about 3.96" My only option is to go thru the cross member. I plan on channeling it with 3"x8" steel tubing.I could probably leave a big gaping hole. But unfortunately there will be a load on the cross member if I do angled winching I might end up tearing the rope on sharp edges. The cross member do fine. I will try to beef up the fair lead mount.
The inner lines are there to show that the fair lead mount that I have will be centered if I rest it on the cross member during installation..what luck.
I will need to get that fair lead mount out to the bumper cover so I can mount the fair lead. This is about where it needs to be 6.5" from the winch plate. I will be adding some reinforcement. That stuff I can figure out at install.
Next hurdle. I am not sure if a 3" opening in the bumper will do.
As long as I can get the winch centered well and I don't go at extreme angles. The rope shouldn't change much based on spool. Assuming a synthetic rope is 3/8" round, which it aint, 4 layers of rope is only 1.5 or .75" in either direction.
Also winch drums are almost 9" wide. My bumper hole will be less than 8". So I have to worry about that.
Do guys think I could do a hawse fair lead on the other side or maybe protrude the 3x8 channel and hammer the sides out so that there's smooth corners?
Here is something I drew up. Need to figure out the "area of concern"
View attachment 211659
Last but not least. The coolant bottle. It drops about as low and the front bumper mounts.
I really had my heart set on the HF Apex 12000 winch, but may not have room. It is loaded with options and plenty strong. Seeing I have a gift card to Amazon, I might go with a Smittybuilt 10k winch or so. It will be smaller and 30llbs lighter. I am getting old and I am not as strong as I used to be.
EODDAVE, what kind of clearance did you have on your coolant bottle?
Forum, what would you do about that inner channel area?
For now project is on hold till I can find a good plate. I already tried 3 scrap yards. A quote for new 40" of structural steel was $83. As opposed to 35cents a pound at scrap yard.