So I'm following the directions in the manual on spooling it all the way out to the last 5 wraps on the drum. I started spooling it in, using co-workers jeep as my anchor.

First layer went fine until it got to the end and started the 2nd layer. It would go up to the next layer and then start to wrap out about 1.5" from the end.

(with controls off) I couldn't fit my hand between the bumper and winch to get it to be tight up against the ride side. We tried and re-tried. Eventually I gave up and spooled it back in without much load, but it did not spool evenly.

I have the AEV bumper, with a roller fairlead. the winch sits down pretty low.

Any ideas?

 

These are the instructions: it doesn't say anything about when it goes from one layer to the next.

Choose a FLAT AND LEVEL location that is large enough to run out the entire length of wire rope.
Turn the clutch lever on the winch to the “Free Spool” position. Grab hook strap and spool out the wire rope to the last 5 wraps on the drum. Once the wire rope is spooled out, turn the clutch lever on the winch to the “Engaged” position.
Attach the hook end of the rope to a suitable anchor point and back the vehicle away from the anchor point until there is very little slack in the wire rope. Before getting out of the vehicle, set the parking brake, place the vehicle in gear or park and turn the vehicle off.
Power in the winch until all of the wire rope slack is wound onto the winch drum. Wearing gloves, hold tension on the wire rope with one hand; carefully push the wire rope to the side of the drum the wire rope is attached to so there are no gaps between each coil on the drum. Be sure to check that the wire rope is winding off of the bottom of the drum, not the top, or the automatic load holding brake will not function properly. (If the wire rope is winding off the top you have powered the winch “out” instead of “in”).
The following steps should be done using two people for proper safety. If you attempt to tension your wire rope alone be sure to always engage the parking brake, place the transmission in gear and turn the vehicle off every time you exit the vehicle to inspect the winch wire rope. Never exit the vehicle with a load on the winch wire rope.
Use care to evenly wrap each layer to prevent damage to the rope.
Instruct your assistant to stand to the side of the vehicle and away from the winch wire rope. Start the vehicle and place the transmission in neutral. Release the parking brake while applying moderate brake pedal pressure. Press power in on the switch. Your assistant should signal you if the wire rope is winding correctly by watching it move across the fairlead as the wire rope is powered in. After winching in for approximately 6 ft, stop winching. Slowly let up off of the brake pedal and then apply the parking brake. This will ensure that there is no load on the winch rope. Then place the transmission in park or gear and turn the vehicle off. Exit the vehicle and inspect the winch to make sure that the wire rope is being evenly wound onto the winch drum and not sinking into the lower layer. If the wire rope is sinking, power the wire rope out and repeat this step from the beginning with more brake pedal pressure.
When you are convinced the wire rope is winding onto the winch drum properly, repeat step 6 until the vehicle is within 3 ft of the winch anchor. Once within 3 ft, slowly let up off of the brake pedal and then apply the parking brake. This will ensure that there is no load on the winch wire rope. Then place the transmission in park or in gear and turn the vehicle off. Exit the vehicle. Disconnect the hook from the anchor. While holding onto the supplied hook strap, hold tension on the winch rope and slowly power in the winch by “pulsing” the power in on the remote control until the hook is at the fairlead. DO NOT POWER THE HOOK INTO THE FAIRLEAD. This could cause damage to the fairlead.