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ground up build

 
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supermanotorious
Backside 180
Backside 180


Joined: 05 Apr 2010
Posts: 518
City: Phoenix

PostPosted: Sep 20, 2012 12:01 am    Post subject: ground up build Reply with quote

The tools:


It begins as a 20' stick of 1 1/4" .083 square tube


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

a little 1/4" flat stock goes into as well


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



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

here is the governor arm on the outside of the block

here it is on the inside

unlike the 6.5HP engines, the governor is located on the side cover which makes for much easier removal


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





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









I lay down the base pieces, clamp, and tack weld





once the base is complete I tack on

uprights:


forward arms:


splash guard and fairlead bar:


and finally supports:


made the motor mounts


test fitted an old starter battery


cut the axle to length (buy them long to make 2 for winches)


drilled the pillow block holes


the motor mount holes


and the bottom splash guard holes


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
















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


splash guard (HDPE)








hitch mount receiver




hitch mount




assembled and shipped today! I work very slowly while assembling to avoid chipping or scratching the paint.

first- the wheels


fairlead



spool assembly


battery tray


motor mounts


motor


wire the electric start




put the chain on


the splash guard


rope and handle


pretty



ship


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Sagittorious
Backside 180
Backside 180


Joined: 12 Jun 2009
Posts: 571
City: Montgomery

PostPosted: Sep 20, 2012 9:06 am    Post subject: Reply with quote

Smash Nice write up! Thanks for showing how its done. I might be pming you soon to ask about tweaking the engine. I started my first winch build over a year ago and still havent finished. Reasons being: 1. My buddy that was supposed to help build it hasn't paid for any parts or even helped with the build 2. Need to purchase a few more parts(new engine or get the one I have fixed, fairlead rollers, rope, chain) other than that I have everything ready to go. Hopefully this winter will be the winter of the winch!
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supermanotorious
Backside 180
Backside 180


Joined: 05 Apr 2010
Posts: 518
City: Phoenix

PostPosted: Sep 20, 2012 10:49 am    Post subject: Reply with quote

thanks, I understand your issue, I've recommended that route to kids without enough cash to build one all at once, there is no problem with slowly accumulating parts, if all you can afford now is the axle, get it and keep it safe, when you can buy the hubs do so, and so on
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supermanotorious
Backside 180
Backside 180


Joined: 05 Apr 2010
Posts: 518
City: Phoenix

PostPosted: Sep 28, 2012 4:05 pm    Post subject: Reply with quote




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