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-   -   ground up winch build (http://www.wakeworld.com/forum/showthread.php?t=795602)

Phoenix_Winch 09-19-2012 10:05 PM

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

Phoenix_Winch 09-19-2012 10:06 PM

spool assembly
http://i12.photobucket.com/albums/a2...psd64af604.jpg

battery tray
http://i12.photobucket.com/albums/a2...psa3f46e71.jpg

motor mounts
http://i12.photobucket.com/albums/a2...ps177d40b5.jpg

motor
http://i12.photobucket.com/albums/a2...ps3f4ef09f.jpg

wire the electric start
http://i12.photobucket.com/albums/a2...ps17a40323.jpg
http://i12.photobucket.com/albums/a2...ps52a0187e.jpg
http://i12.photobucket.com/albums/a2...psf51abe93.jpg

put the chain on
http://i12.photobucket.com/albums/a2...psde96ce1f.jpg

the splash guard
http://i12.photobucket.com/albums/a2...ps02ab8d6d.jpg

rope and handle
http://i12.photobucket.com/albums/a2...ps31f3815d.jpg

pretty
http://i12.photobucket.com/albums/a2...ps49fd69e6.jpg
http://i12.photobucket.com/albums/a2...psef709a5f.jpg

ship
http://i12.photobucket.com/albums/a2...pseb81e634.jpg
http://i12.photobucket.com/albums/a2...psc9f224c7.jpg

saberworks 09-22-2012 8:29 PM

I've never done any winching or cable, but thanks for posting these pictures, the build-up is cool.

wakeboardingdad 09-22-2012 10:31 PM

That was a great build out and you showed a lot of information about your design and processes! Very generous.

Phoenix_Winch 09-28-2012 2:06 PM

http://www.youtube.com/watch?v=mfsU-Fwjazk&hd=1

bryce2320 09-28-2012 2:59 PM

That thing is awesome. Great job!

Phoenix_Winch 10-01-2012 10:13 AM

thank you all for checking it out

tyler97217 10-01-2012 10:16 AM

Cool post!

wakeboardertj 10-01-2012 11:50 AM

Righteous! Thanks for posting your build design I've been wanting to put my welder to use


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