Thanks guys, this has been a real help. I was just staring at a couple of thousand dollars worth of steel thinking 'well that was a f*@#%^g expensive mistake'. Do'h.
Ok, so for those watching and wondering or for future reference for other DIYers installing a 9500lb ironman winch with synthetic rope on an xrox bar- (I'm not sure about steel cable and rollers - the ironman winch with cable is a different model so probably has different mounts) here goes. Let me know if anything is not clear.
The xrox bar does NOT come with a cradle to mount a winch (verified by Outback Accessories) - I thought maybe it had been left off mine during production - these things happen - or it was a separate purchase item - but no, it just doesn't have one. The winch is mounted straight onto the inside of the bar (the forward face) using the 4 holes that will match up with the mounts on the winch, which is apparently a standard adopted by most winch manufacturers. You DO NOT have to pull the winch apart to adjust the clutch etc - by mounting it flat against the front of the bar the the engage/disengage switch is perfectly situated in the cutout in the top of the bar. That'll save an hour of so.
Here's where I got stuck - The hawse fairlead that is provided with the ironman winch is straight, so logic says it should fit straight across the gap in the bar where the rope comes through - the instructions aren't very clear about this (I'm assuming now that the instructions are referring to installation on a cradle) but there are holes in the bar for this so thats where I thought it should go - but it will not fit here because there is no room for the bolt to go through and fit a nut because it hits the winch, which is almost flush against the inside of the bar. To get around this you have to purchase an additional hawse fairlead that is 'offset' - the fairlead then shares the same bolts as the bottom mounts of the winch. I wasn't aware that the hawse fairlead could share the same bolts as the winch itself but I've since been told that its pretty standard and creates a clamping effect further reinforcing the bar. Maybe the instructions with the winch should mention this possibility........ but hey that's what the interweb, phones and forums are for hey?
I haven't figured out how much offset is required as yet. There 15 or 25mm options, possibly more. I'll update this when I know.
You also have to fabricate a bracket to mount the solenoid/control box on the bar, or mount it somewhere else - I've heard of someone mounting it in the engine bay because they didn't have enough room on the bar due to driving lights (the hoop on the bar is a little restrictive if you want to mount MOFO lights and a solenoid), but they were using a different type of battery that was smaller and therefore provided more room. I dont know about you guys but my engine bay is a bit crowded. I'd love to see some pics of mounting brackets if anyone has some.
Hopefully I get the bar on this weekend now I know what the hell I'm doing. Hah. Famous last words