Rough Country Winch/MetalTech 4 x 4 Bronco 6G TFFR (Total Front Frame Reinforcement) kit install

Roughstock

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Jul 1, 2023
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2023 Shadow Black Raptor
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2023 BMW GS 1250 Adventure
Hi all!

The install went well. Tough at times but worth it.

RC high winch mount, MetalTech 4 x 4 Total Front Frame Reinfocement (TFFR),m M2M camera relocate kit, Warn Zeon XD 12s, Factor 55 Ultrahook and rope protector

Two men sixteen hours to install with some extras like painting and camera relocation. One day six hours and the next day 10 hours with basically no breaks.

The hardest part was the MetalTech's TFFR. Someone on here mentioned with another install they don't show you how it's done because it is a hard install and you may not want to do it after watching an install video. We found this install difficult. I asked Metaltech if there was anything different on the Raptor and they said there shouldn't be and sent me a video of them telling us how to install (a bench install video) saying one day they would show us how to do it on the vehicle.

The first thing we did was to paint the front bash plate and the front plastic.

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Then we took the bumper off. The bumper comes off with six bolts. Three on each side.
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Then the TFFR instal. One set on each side. Plus of course the hardware.

Thee are a few other manufactures of frame horn supports. I found these to be the best and most substantial and probably the hardest to install.

From there web site.

The TFFR or Total Front Frame Reinforcement kit is a 100% bolt-on external and internal front frame horn reinforcement system.

  • Boxed side supports for each frame horn (total of 4)
  • Internal support bracing inner part of frame
  • Top of frame supports integrating whole system
  • 100% bolt-on - with no drilling or modification
Total reinforcement is achieved using fully boxed and welded reinforcement brackets to externally reinforce each side of the front frame horns. Internally, a crossbar system ties the two boxed frame horn brackets together, supporting your frame's internal box structure. Next, on top of each frame horn, a T bar bolts to both sides of the boxed brackets and reaches back 6" on top of the frame to an existing bolt, distributing all front frame horn loading across the most area possible without drilling or welding. This proven system is designed to work with the Metal-tech 4x4 Bronco Stronghold Winch mount but can be used with other bumper systems. Easy 100% bolt-on, no modifications to the frame.

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Here's a picture of the frame horn. Three pieces on each horn. This pic has the top T piece on it which they said to start with. Also, you can see the bolt sticking though the frame horn which the brackets attach too.

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This pic shows the top and one side bracket. Of course the other bracket is on the other side of the horn
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This is a good pic of the top bolt on the T bracket that you need to take out (it holds the intercooler) and put a washer on it and put back in and slide the bracket into it. In the MetalTech video they it is doable. It is doable as we did it but I can ensure you that it is very tough. You can barley get in there to turn the bolt. We didn't have a ratchet wrench which would have perhaps helped if you could get it over the bolt. It still would be hard.

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It is amazing now it doesn't look that hard but it was perhaps four hours. There was a lot of fiddling to get the entire bracket on and we had to loosen one bracket getting the bumper back on as it had pulled away when we tightened it and the bolts were too short. We pulled it back flush with the bolts only and then put the tow hook on. We were happy it worked. We didn't have longer bolts. They are pretty big bolts and probably not something you have in your bolt supply.

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Camera relocate was pretty straight forward and the winch mount and winch instal were straight forward. You have to take the front grill off to get at the camera and thankfully it came off easy. The second hardest part was probably cutting the plastic to fit the winch mount. It took a couple hours as we did it bit by bit to fit. It turned out great. Half way through it didn't seem like it was going to but it turned out real well. We gave it another coat of paint once cut. There is a lot of fiddling with all of it. It seems the manufactures expect you to have some basic mechanical skills as you have to use your common sense at times.

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We were real happy with the install once done. I am leaving off my DV8 D rings as they are gloss black and they don't look good anyway with the winch mount. The tow hooks will be just fine by themselves especially with rope chafe protection.
 
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you should upgrade to Factor55 1.0 fairlead. it is much better and is not expensive.
I was going to and when I spoke with Warn the guy seemed to think the upgraded XD fairlead was good. I think the Factor 55 would still be better so we will see what the future holds.
 
L👀king good @Roughstock - 16 hours with 2 guys is some serious effort, kudos.

Did you connect the power directly to the battery or did you install an in-line cut off switch or solenoid? Also, do you have a wireless controller or is it wired?
 
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L👀king good @Roughstock - 16 hours with 2 guys is some serious effort, kudos.

Did you connect the power directly to the battery or did you install an in-line cut off switch or solenoid? Also, do you have a wireless controller or is it wired?
Directly to the battery. Correct me if I am wrong. Is not the winch "on a solinoid pack, which means that two seperate solinoids would have to BOTH fail, and both fail at the 'on' position. Remembering of course, that when solinoids typically fail, they fail in the 'off position" (" " info. taken from another post). If I understand this correctly you do not have to put a switch on the winch motor power. I would like to know your thoughts. Or are you thinking about fires and such. It shouldn't drain the battery as the motor is not on. Correct?

It also has a wired controller and a wireless controller with a blue tooth to phone app. The platinum comes with a completely wireless unit.

I haven't used the wireless option yet. I will check it out soon. I am Ok with the wired control so having a wireless option is a bonus.
 
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Because the winch is expected to wired direct to battery, I fabbed up a bracket and wired mine to a waterproof battery cut off switch that I mounted just in front of the battery. While not “required”, I installed it this way just as a precaution to protect against any power draw from the battery while the winch is off - it’s cheap insurance. The Braptor is not my daily so it can sit around for a bit unused sometimes and I just wanted to be (extra) safe.

I like the idea of wireless control and I am considering an add-on module for my Zeon 10S. I don’t know however how much if ever I would actually use it. Winching control can get a bit technical and I like the control and practicality of a hard wired switch but the allure and convenience of wireless is certainly appealing. Decisions, decisions…
 
I have mine wire with cut off switch under the hood as well, I been told to setup this way the whole time.
1 - dont want anyone power up my winch when i park on the street or mall LOL
2 - don't want anyone or chance short circuit the battery to cause fire

Something like this, no solenoid, just simple cut off switch
Screenshot 2024-12-10 at 10.43.35 AM.png
 
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Because the winch is expected to wired direct to battery, I fabbed up a bracket and wired mine to a waterproof battery cut off switch that I mounted just in front of the battery. While not “required”, I installed it this way just as a precaution to protect against any power draw from the battery while the winch is off - it’s cheap insurance. The Braptor is not my daily so it can sit around for a bit unused sometimes and I just wanted to be (extra) safe.

I like the idea of wireless control and I am considering an add-on module for my Zeon 10S. I don’t know however how much if ever I would actually use it. Winching control can get a bit technical and I like the control and practicality of a hard wired switch but the allure and convenience of wireless is certainly appealing. Decisions, decisions…
I may look into doing the same thing. I believe there should be no power draw but that is easy to say without really knowing.
 
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I have mine wire with cut off switch under the hood as well, I been told to setup this way the whole time.
1 - dont want anyone power up my winch when i park on the street or mall LOL
2 - don't want anyone or chance short circuit the battery to cause fire
It sound like the way to go. Next project coming up....ha
 
NB - make sure to properly size the wire & switch to the winch amperage draw so you don’t actually create a problem. The Zeon 10S has a max draw of 409 Amps and my switch is sized at 455 Amps at 12V.
 

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