2011 Big Boss 6x6 and winch mounting

HuntNphotos

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Let me start off by saying that if you have considered buying the new 800 big boss 6x6 this is the year to do it. The few issues I have heard from the past two years models have definitely been taken care of and this thing is a beast!
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That being said, be carefull of the winch you chose! I found an incredible deal on a winch that I have heard nothing but good things about and ended up picking it up before I even closed the deal on the machine. It was a 3500# Superwinch Terra 35 and from the reviews and specs is every bit as good as the warn with the same exact warranty but at much less than half the price! In fact, the only real difference between it and the Warn is the body size dimensions. That being said, on this machine, that makes a huge difference.

Being a totally redesigned front end there were no mfg's that made an aftermarket winch mount except for Polaris when I picked up the machine. And Polaris would only sell the mount as part of the kit with their winch. So, shortly after I picked up the machine I contacted KFI fabricators. I had heard they were working on a mount for the new xp and that it would work on the big boss, but they had never tried it with my winch.

After recieving the mount to test for them it was obvious that the winch would not fit inside the mount. I called them back and told them the dimension differences and they told me that they didnt think they would be able to mfg one for that winch with the limited numbers they expected to sell. The did, however, let me keep the mount to modify myself and try to make it work. With no other options available yet that is exactly what I had to do.

To make the winch fit I had to cut the winch mount across the top where the winch mounts and raise it up 1/4" with a cut down piece of angle iron.

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Then I had to do a tad bit of filing and grinding to make it fit on the machine and mount. The mount is designed for the sportsman xp but works with the big boss as well. The clearance now between the mount and radiator is very tight, but there is no flex in the mount so there will not be an issue there.

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HuntNphotos

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Some more pictures of test fitting the mount.

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Then the fun part began. To get the winch into the mount and get them both bolted up I had to first unbolt the mount and put it inside the frame at an angle. Then I had to start putting the winch in the mount and turning it into the frame rails at the same time. This was after several attempts to get it in there any other way! But in the end it fits in there very snug, but solidly!

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stid2677

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Looks very nice, got to love Alaskan ingenuity. Just FYI, I have been told that synthetic rope don't wear well with a roller fairlead. Mine came with an aluminum fairlead to go with the synthetic.

Great looking rig.

Steve
 

HuntNphotos

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Thanks guys! Steve, that depends on which mfg you talk to. there were two reasons that the rope had issues with the rollers. One is that people were installing the rope with a roller fairlead that was previously used with a cable. In that case there are usually burs and scuffs on the rollers that would quickly destroy the rope. The other issue is that some of the rollers had a little slop in them and the rope could be pinched or slid between the mount and roller at certain pulling angles and damage the rope. If you have a good new roller fairlead designed for the rope several mfgs actually recommend the roller to the hawse fairlead. I also have rope on my 2004 Arctic cat that has been used and abused heavily for 6 years now with a good roller fairlead and the rope is still in really good shape!:topjob:
 

stid2677

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Better not put that checkbook away just yet. That thing will need some new monster tires, a tricked out rack, gunrack, and a few other things that I'm sure you can't live without. :)

It's only money and it doesn't matter until you don't have anymore..LOL

Steve
 

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