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New winch build from New Zealand / How To (56kbps watch out)

 
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chappell943
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PostPosted: Mar 21, 2013 3:16 am    Post subject: New winch build from New Zealand / How To (56kbps watch out) Reply with quote

This is a write up of how my third winch was built. The winch was built by two of us over 4 days and 60 combined hours.
Parts required:
Tav2 (went with a 12T sprocket made for #35 chain)

9hp Engine (6.5hp will be enough to deep water start upto roughly 90kgs if 9hp is out of your budget or you are trying to keep weight down.)

Rope (I used 7/64 amsteel blue and got 280m which I find to be perfect and it is amazing winch rope!)

Spool materials (We used two 16” cnc cut 3mm steel discs.)

Metal for frame and spool bolts (we bought 8m of 40mmx40mm 2mm box section and had about 2m left over, for the spool bolts we used 16mm steel rod.)

Axle and hubs

Sprocket (Don’t have a picture of this but just get a sprocket which gives you between a 1-5 and 1-6 gear ratio and suits your chain pitch)
Fairlead (No picture but type in ATV fairlead in Ebay and you’ll get the idea)
Pillow Blocks (Forgot the photo but you can see them later on holding the axle onto the frame)
Chain (Self explanatory but either get a #35 or #40 depending on what TAV2 and sprocket you bought.)
Wheels


The Frame

The frame is relatively self explanatory from looking at the pictures below but we basically made the frame from the back to the front (rear piece, then engine mounts, etc…) If there is enough interest I could write up a measurement/cutting list but in my opinion it is much easier to just buy all the parts and then test fit and make your own decision about how big or small to make everything. Don’t forget to brace where the spool attaches too as that will see quite a bit of stress when the winch is being used.










Painting The Frame
First we wiped the whole frame down with paint thinners to get all grime, grease and dust off it. We then sprayed two coats of primer on it and let it dry.

After this we choose our final paint colour (we went with a crinkle black). We then sprayed 3-4 light coats on the frame about 20mins apart and then gave the frame 48 hours to dry and harden. This is the final result.



With the frame all done it was now time to go ahead and prep the engine. On the frame there are a total of 6 holes and 4 slotted engine mounts. Two holes either side for the pillow blocks and then two holes for the fairlead. For the engine mounts we test fitted the engine and then used a jigsaw to create slots which mean we can tension the chain easily.
Engine Prep
Now usually with most engine and TAV2 set ups there is no engine prep apart from filling with oil, petrol and bolting the TAV2 on, Unfortunately for us we had fitment issues with the TAV2 fouling on the dipstick of the engine. To sort this out we had to remove the crank cover on the engine, cut the dipstick off and then weld it up. There aren’t many photos of this due to just wanting to get the dam thing mounted up, after cutting and welding where the dipstick we still had fitment issues so we had to grind a small portion of the TAV2 out. Neither of these “modifications” will harm either the engine or the TAV2 in any way. The TAV2 still has plenty of support and we were very careful at getting all metal filings out of the crank cover before reattaching it.

Welded from the inside:


Spool
Now as most people say the spool is the hardest part of the winch to build and that isn’t a lie, it took close to the same amount of man hours to build the spool as the frame took. If you have the option I recommend drawing up a CAD drawing of exactly what you want and taking it to get CNC cut to perfection. What we choose to do is to get just the 16” circles CNC’d and we drilled and measured all the holes ourselves.
If you can’t afford to get the holes drilled or just want to do them yourself then this is how we marked all of our holes.
1. When you get the circles they should have the centers marked, if not measure across the disc and find the longest point, then mark halfway. Turn the disk 90 degrees and do this again and the center is where these two lines intercept.
2. Once you have found the center get a 360degree protractor and mark out 6 points at 0,60,120,180,240 and 300.
3. Now get a ruler and draw lines from the center hole of the spool wall and draw the lines out from the center to the edge wherever there is a 60 degree mark.
4. Now get a ruler and measure and mark up one of the lines 2.25”, 3.25”, 4.25” and 5.25”
5. Get a compass and draw circles from the center at each of the above measure points.
6. You should now have 6 circles coming out from the center hole as well as each circle having 6 intersections.
7. These 24 marks (6 marks on each circle, 4 circles) represent where you need to drill an 8mm hole.
8. We did all our spool holes with the two sides clamped tightly together so we could get them as accurate to each other as possible.
9. For the axle and hub hole we did this last and we simply measured our hub size and drilled a hole in the center and then marked and drilled the 4 hub holes using a hub as a guide.





Now to create the spool rods we used 16mm high tensile steel rod. We cut 6 rods at exactly 152cm (6”), we then drilled 30mm into each end and put an 8mm tap into the end of the rod.


Painting The Spool
Painting the spool was pretty much the same process as the frame, we wiped the spool walls and rods down with paint thinners, primed both and then painted one side of the spool crinkle red and the rods and inside of the spool gloss black.





It was then time for us to bolt the hubs on and connect the spool sides together with the threaded rods, we used a spring and flat washer on the spool rods and used ny-lock nuts on the hubs.
Finished Product!

Assembly Time
Assembling the winch is relatively straight forward.
1. Take your axle and slide in the keyway, then slide on the sprocket with the hub, then slide on your spool .
2. Take your two pillow blocks and put one on either end of the axle and attach these to the frame.
3. Take the engine and bolt it loosely to the frame (will explain why soon)
4. Bolt the fair lead in to the frame with two nuts and bolts.
5. Put the chain round the tav sprocket and round the upper sprocket making sure they are aligned as close as possible.
6. Once they are aligned tighten up grub screws on the pillow blocks and the hubs (this is to stop the axle moving round and to stop the spool or sprocket moving.)
7. Pull the chain as tight as possible and mark where the chain needs to be cut at.
8. Cut the chain and then attach a chain link
9. Get your mate to pull hard back on the motor while you do up the engine mounts (This is the best way I have found to get the chain tight.)
10. Start up the engine and wind the rope on
11. Go use the thing!






Winch made by Blair and Taylor
Write up by Blair.
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frankycouplepuphs
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PostPosted: Mar 22, 2013 9:26 am    Post subject: Reply with quote

Very Happy



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Sagittorious
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PostPosted: Mar 25, 2013 1:38 pm    Post subject: Reply with quote

Smash Way to go guys! Happy winching! Smash
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chappell943
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PostPosted: Mar 25, 2013 7:56 pm    Post subject: Reply with quote

Video from the weekend

http://www.youtube.com/watch?v=JNjdpbCppVc
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Sagittorious
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PostPosted: Mar 26, 2013 4:19 pm    Post subject: Reply with quote

Damn it pulls like a beast!
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bs
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PostPosted: Mar 27, 2013 4:46 pm    Post subject: Reply with quote

that video was so sick. props.
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paulmc
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PostPosted: May 30, 2013 7:10 am    Post subject: Reply with quote

lovely!
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bondmaxbondrock
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PostPosted: Jun 09, 2013 9:26 am    Post subject: Reply with quote

That is sick! How much did it cost to build all said and done?
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chappell943
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PostPosted: Jun 11, 2013 12:10 am    Post subject: Reply with quote

All up it cost $2137 New Zealand dollars, reason it is slightly expensive is that 25% if not more was shipping costs without shipping costs it would be roughly $1300 USD.
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bondmaxbondrock
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PostPosted: Jun 11, 2013 9:50 am    Post subject: Reply with quote

Ah that's a little out of my budget right now haha. Was thinking about making one to use for wakeskating and snowboarding and stuff though
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PostPosted: Jun 11, 2013 10:07 am    Post subject: Reply with quote

winches arent cheap bro.

i am gunna start getting the pieces together this winter, when i have nothing else to do.

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