HuntNphotos
Well-known member
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!
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.
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.
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.
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.
