Whatever you call them the ability to utilize the
front mounted winch on a Dodge Power Wagon for lifting is something thats
very handy to have around the neighborhood. The following plans illustrate
the construction of a set made by the author. This material is presented
for reference only and no guarantee or warranty is implied.
In the photo attached a red ratchet strap is used
to prevent the poles from bouncing while driving. The mounting brackets
for the poles contain a stop to prevent the poles from flipping back over
A cable from the winch runs to the top of the poles
and around a sheave.
The first step is to get (2) long pieces of pipe.
The pipes pictured above are 2 schedule 40 pipe 12 feet long. (Schedule
40 is a term which describes the thickness of the pipe wall, this is the
standard or most common size). Cost is about $2.25 per foot.
Next the following pieces must be cut, drilled, and
The bracket assembly shown above bolts to the frame
with ½ bolts to anchor the poles. These brackets use the
mounting holes on the winch extensions that were intended for the tow hooks.
A ¾ diameter pin or bolt thru these brackets holds the poles in
place. Use of a pin allows quick removal of the poles. You
can save some material and cutting if you arrange the pieces as shown to
cut out of a piece 8 ½ long.
The upper end assembly shown uses a 7 diameter sheave
with a ¾ diameter pin. You may wish to modify this piece
depending upon the size of sheave available.
The lower end pieces are inserted 3 into the lower
end of the pipes and welded in place. These pieces must be parallel
to each other and 30 ¾ apart. An easy way to do this is to
use a 36 long piece of threaded rod and nuts on each side of the lower
end pieces to keep them spaced correctly.
After bolting the lower end pieces together lay the
pipes on a flat surface like a garage floor. Slide the lower end
pieces 3 into the pipes. Then position the upper end of the pipes
against each other. Slide the upper end assembly 3 into the pipes.
Weld the upper and lower end pieces to the pipes. Weld the 2 pipes
to each other at the top.Weld a piece of 1 schedule 40 pipe between the
(2) pieces of 2 pipe approximately 64 up from the bottom of the poles.
The chain brackets weld to the pipe 8 feet up from
the lower end. Two of these weld to each pipe ½ apart.
Refer to previous drawing of the poles. A 7/16 grade 8 bolt passes
thru these to hold the chain to the poles.
The filler pieces are used to close off the end of
the pipes and are also welded to help hold the upper and lower end pieces
inside the pipes.
2 square tubing 1/8 wall thickness can be used to make a frame for the bed. The frame should be at least 3 to 4 higher than the cab of the truck to keep the chains from scratching the roof. A plate with a slot in it on each side of the top of the frame is used to hold the chains that run over the cab to the poles. The slot allows the length of the chains to be easily adjusted to change the angle and height of the poles. The chains should be at least 5/16 and a minimum of 14 feet long.
Brackets on the vertical portion of the frame are used to attach the chain that is anchored to the bed. This chain needs to attach to a cross-member of the bed or bolt thru to the frame of the truck. Do not just attach it to the sheet metal of the bed.
2. Pull enough cable off the winch to extend
around the sheave and go back to the bumper of the truck. Install
the pin on the cable guide to keep the cable on the sheave.
3. Use 3/8 grade 8 bolts or 3/8 pins to fasten
the chains to the chain brackets on the poles.
4. Lift the poles up and place the wooden prop
under the 1 piece of pipe connecting the 2 pipes.
5. Place an old blanket on the roof of the cab
to keep it from getting scratched.
6. Connect the chains used to brace the frame
in the bed to the truck or bed frame.
7. Stand in the bed of the truck and have an
assistant walk around the side of the truck and hand you the opposite end
of the chain attached to the poles. The assistant then moves to the
front of the truck and holds the chain off the fender and hood. The
person in the bed of the truck pulls the chain tight and hooks it in the
slot in the frame above the cab.
8. Use the same procedure to attach the chain
on the other side of the truck.
9. Adjust the poles to the desired height and
angle by alternately adjusting the chains on each side of the truck.
By adjusting only 2 to 3 links at a time the chains will stay off the roof
of the truck.
10. Add a chain or ratchet strap from the 1
pipe down to the bottom of your front bumper to prevent the poles from
bouncing as you drive.
With a little practice the poles can be installed
or removed in 5 to 10 minutes. Use common sense when lifting or moving
items with the poles.
Direct any comments or questions to Ken Kull email@example.com