Storing and protecting a winch on a car hauler is crucial. An ideal solution is integrating it into a tongue-mounted toolbox. This article details a DIY approach to installing a winch inside a toolbox on a car hauler, providing a secure, weatherproof, and convenient storage solution.
A freshly painted car hauler tongue with the installed winch box.
A car hauler often needs a winch for loading vehicles, especially project cars. While various winch mounting options exist, integrating it into a tongue toolbox offers several advantages. It protects the winch from the elements, theft, and damage, while keeping it readily accessible. This article outlines the process of converting a standard job box into a custom winch enclosure.
Choosing the Right Toolbox
Finding a suitable toolbox is the first step. While pre-made winch-ready boxes are available, a cost-effective alternative is repurposing an existing job box. This project utilized a 30″ x 16″ x 12″ steel welder’s job box, offering ample space for the winch, battery, and accessories. Ensure the chosen box provides sufficient internal dimensions for your specific winch and other components.
The repurposed welder’s job box before modifications.
Preparing the Toolbox and Trailer Tongue
Before mounting the winch, prepare the toolbox and trailer tongue. Seal any existing holes or gaps in the job box with sheet metal patches and silicone sealant to ensure weatherproofing. Next, fabricate a mounting platform on the trailer tongue using steel tubing. This platform should raise the toolbox to deck height, preventing the winch cable from dragging on the trailer deck.
Initial framework construction on the trailer tongue.
Reinforce the platform with cross members and a steel plate to provide a solid foundation for the winch. This ensures the winch pulls against a robust structure, preventing damage during operation. Modify the trailer’s front crossmember if necessary to accommodate the toolbox and fairlead.
Completed steel deck ready for the toolbox and winch.
Mounting the Winch and Accessories
After preparing the platform, bolt the winch securely to the steel plate. Use high-grade hardware for a reliable connection. Position the battery and control box inside the toolbox, ensuring adequate ventilation and accessibility. Drill a hole in the box for the winch cable exit and install a rubber flap to prevent water intrusion.
The winch mounted inside the box, showcasing the tight fit.
Wiring and Final Touches
Wire the winch according to the manufacturer’s instructions, paying close attention to color-coded connections and grounding. Mount the remote control receptacle in a convenient location. After completing the wiring, add weatherstripping around the toolbox lid for a tight seal.
Inside the finished box: winch, battery, and control box.
Consider adding organizational features inside the toolbox for straps, shackles, and other recovery gear. This maximizes space utilization and keeps essential equipment organized.
Conclusion
Building a custom inside toolbox for a car hauler winch offers a practical and affordable solution. By repurposing existing materials and following these steps, you can create a secure and weatherproof enclosure for your winch, ensuring its longevity and readiness for use. This DIY approach not only saves money but also allows customization to fit your specific needs and preferences. Remember to prioritize safety and use appropriate personal protective equipment throughout the process.
