ground up winch build
The tools:
http://i12.photobucket.com/albums/a2...1D9B43007D.jpg It begins as a 20' stick of 1 1/4" .083 square tube http://i12.photobucket.com/albums/a2...1D9780D055.jpg The tube gets cut into several pieces, there are only 2 90 degree cuts so they get done first, then come the 45 degree cuts http://i12.photobucket.com/albums/a2...1D9FB8325B.jpg a little 1/4" flat stock goes into as well http://i12.photobucket.com/albums/a2...1DA30D9FB9.jpg I'm waiting on parts (which I'll provide a comprehensive photo once they're here) so I decided to de-govern the Predator motor http://i12.photobucket.com/albums/a2...1DA7238E00.jpg http://i12.photobucket.com/albums/a2...1DAB7F304B.jpg lay the engine on it's side and remove the 7 side cover bolts (this is because there is some factory oil in the block that will run out if the engine is upright), the bolts will be replaced at 17 ft lbs http://i12.photobucket.com/albums/a2...1DB1B29599.jpg here is the governor arm on the outside of the block http://i12.photobucket.com/albums/a2...1DB7C3DF61.jpg here it is on the inside http://i12.photobucket.com/albums/a2...1DC5AEAA0D.jpg unlike the 6.5HP engines, the governor is located on the side cover which makes for much easier removal http://i12.photobucket.com/albums/a2...1DBB9EB8BE.jpg ok ok so there are a few more tools involved than I pictured but you'll get to see pictures of them too I build 5 spool cross members into my winches where most use 6, they're totally sufficient and make me just a little more unique what I'm creating here are the cross member shrouds, they serve 2 fold: protect the line from exposed threads on the bolt, and they keep the spool walls at a fixed distance from each other http://i12.photobucket.com/albums/a2...0BAED93BAE.jpg http://i12.photobucket.com/albums/a2...0CBE4FF3DA.jpg http://i12.photobucket.com/albums/a2...0CD5CA4975.jpg an exclusive of Phoenix Winch, I weld all metal lock nuts inside the frame so bolts can be used as axles and wheels can be removed if necessary http://i12.photobucket.com/albums/a2...FFD7DF34C1.jpg http://i12.photobucket.com/albums/a2...0470913A2D.jpg http://i12.photobucket.com/albums/a2...FFFD871C0E.jpg http://i12.photobucket.com/albums/a2...00088F81F1.jpg I lay down the base pieces, clamp, and tack weld http://i12.photobucket.com/albums/a2...0551FA958C.jpg http://i12.photobucket.com/albums/a2...0557A0EE45.jpg once the base is complete I tack on uprights: http://i12.photobucket.com/albums/a2...43EE0127ED.jpg forward arms: http://i12.photobucket.com/albums/a2...43F5D4AF7E.jpg splash guard and fairlead bar: http://i12.photobucket.com/albums/a2...43F9D8ED2F.jpg and finally supports: http://i12.photobucket.com/albums/a2...43FDD06817.jpg made the motor mounts http://i12.photobucket.com/albums/a2...36670177E6.jpg test fitted an old starter battery http://i12.photobucket.com/albums/a2...366F68C43A.jpg cut the axle to length (buy them long to make 2 for winches) http://i12.photobucket.com/albums/a2...36789FF9F8.jpg drilled the pillow block holes http://i12.photobucket.com/albums/a2...367CDB2FA2.jpg the motor mount holes http://i12.photobucket.com/albums/a2...3680E866F9.jpg and the bottom splash guard holes http://i12.photobucket.com/albums/a2...3685206756.jpg got some more done today, picked up spool walls from wajerjet friend and assembled, then test fit and broke the chain, with spool in place I tacked welded the fairlead mounts http://i12.photobucket.com/albums/a2...ious/011-4.jpg http://i12.photobucket.com/albums/a2...ious/012-2.jpg http://i12.photobucket.com/albums/a2...05FB05DE4E.jpg http://i12.photobucket.com/albums/a2...097063446C.jpg http://i12.photobucket.com/albums/a2...0F6BB3B34C.jpg http://i12.photobucket.com/albums/a2...0F8C5B118E.jpg http://i12.photobucket.com/albums/a2...10195DABA3.jpg sorry for an overdue post, its pretty typical in these builds that by the time I get to this point I feel like forget the camera, its balls out fabrication time so I fabricated the battery tray, splash guard, and hitch mount, welded the hitch mount receivers to the frame as well as the fairlead mount and splash guard tabs I got the sprocket, frame, and hitch mount painted and they look incredible, black is really the only color winches should be allowed to be I'm going to give the paint plenty of time to cure then its time to assemble, spool the line, build the crate, and ship this bad boy to Cali, this build will tow riders up to 35 mph! (may not seem like much on the street but it's overkill for a wakeskater unless he wanted to break a bus jumping record or try his hand at some barefoot skiing) battery tray http://i12.photobucket.com/albums/a2...0FA4592E95.jpg splash guard (HDPE) http://i12.photobucket.com/albums/a2...0F9FA94AFC.jpg http://i12.photobucket.com/albums/a2...0F9B18EAE7.jpg http://i12.photobucket.com/albums/a2...0F7CAA4579.jpg http://i12.photobucket.com/albums/a2...0F80BD9740.jpg hitch mount receiver http://i12.photobucket.com/albums/a2...0F860CB205.jpg http://i12.photobucket.com/albums/a2...0F8A486B5F.jpg hitch mount http://i12.photobucket.com/albums/a2...0F8F46EA0F.jpg http://i12.photobucket.com/albums/a2...0F953F5053.jpg assembled and shipped today! I work very slowly while assembling to avoid chipping or scratching the paint. first- the wheels http://i12.photobucket.com/albums/a2...ps89c3f4ff.jpg fairlead http://i12.photobucket.com/albums/a2...ps6f6c3aa6.jpg http://i12.photobucket.com/albums/a2...psd371a4ce.jpg |
I've never done any winching or cable, but thanks for posting these pictures, the build-up is cool.
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That was a great build out and you showed a lot of information about your design and processes! Very generous.
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That thing is awesome. Great job!
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thank you all for checking it out
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Cool post!
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Righteous! Thanks for posting your build design I've been wanting to put my welder to use
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