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Husky winch Refurb & Bumper build

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Hi Everyone

Time for a bunch of pics from my refurb and winch install onto my series 3.

So i managed to bag a bargain off ebay, and this is how it arrived.



So time for a strip down and see what it needed, as its had a hard life on the rear of a recovery truck from what i could find out.



It was not in a such a bad shape, worn brushes, and lots of grime and neglect. I started off by ordering new brushes



After some prep i had the whole thing painted in Grey, plus some new gaskets and plastic cover from the UK


Got the commutator polished and started reassembly. Old VS New brushes.



Fully assembled back to its glory




Than it was time to start the Fabrication for a new bumper to accommodate the winch. I was lucky enough that the sale of winch had the winch plate included (had it blasted), so i incorporated that into my build. Now i wanted a specific style of bumper which was mounted higher than standard and looked more or less like what i had before ( standardish looking) . So went out and got some RHS........ and started mocking things up.


To save on fab time i decided to use my old bumper as a doner for the chassis mounts (easier i thought at that time) and grafted them onto the RHS......... 


Next a quick check that it looked ok.......


So i got some 3mm plate and doubled up the top and bottoms, tieing in the the old bumper mounts, its a lot of welding but the result was pretty pleasing.







I then added some gussets at the old bumper mounts to make sure it will not go anywhere 



Than it was the light bars turn to be fitted, since i always liked the shape it was in, and its been on the vehicle trough the 3 bumpers i thought it was only appropriate that it gets reused.


Its than off to the galvanizers for that series look...............


So next was vehicle fitting............ i already had an extra X member right at the front at the dumb irons, so i added some more Gussets at the corners.






And finally mounting the whole lot back onto the Landy..............












This is where i am the moment, next is wiring the winch up with an aftermarket winch control box. Than time for a new synth rope.


Hope you all find it interesting, sorry for the long pic heavy post................


Regards Grem

Edited by Gremlin
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I followed your work on Facebook, Patrick.  Impeccable as always!  I fancy something similar to lower my winch a bit and allow the use of a full rad grille - I’m not fond of the bikini mount and how high it places the winch, even though it does allow the number plate to be sited permanently on the bumper and doesn’t seem to harm engine cooling with the winch’s solenoid bridge cut into the grille.

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Thanks, i have noticed that after i added back the spotlights the electric fan comes on more often, so they are probably hindering the airflow. Since i do not have long journeys on this little rock, so they will stay like that, the fan will keep up anyway.

Next instalment will the the solenoid and related large gauge wiring. I was going to install it in the wing behind the lights, but its a headache to get to if it goes wrong for some reason, so its going in the front next to the winch, in a similar location of the originals. The solenoid kit (allbright clone) i got is mounted in a watertight box, so it should be ok. Anyway not much water round here.


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What?  There’s water ALL around there!  It’s a lot deeper than you want to wade in, and that snorkel won’t be nearly long enough, but it’s there all right!

Took a blurry photo on the way past (eastbound) around midnight last night.  Lots of fireworks.  Siggiewei (not a chance I spelled that right) is just a little to the left of the pinkish blob near the right hand end.


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Brilliant Nick, if you are ever on the rock let me know.

Short update, trimmed the front apron to hug the winch, now it looks finished.


Also painted and finished the bracket to mount the control box, pics tomorrow...........



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Update, probably the final one.

Solenoid control box Bracket all fabbed up and painted



Next up the box as received (its ment to go on low line winches). I opened it up to see the internal gubbins and quality. Its a Chinese thing and i had to change the cable to the motor as they were too short for my application In my view i saw that the crimped wires and terminals seemed weak, so i went out and upgraded the wiring from 25mm2 to 50mm2.......... thought it was simple, but unfortunately twice the wire size did not make the cables really flexible, so i had to be a little creative.  




So after a lot of twisting and head scratching i ended up having to relocate the terminals for the contactor via short copper bus bars, in order to retain the thicker cables. Installed a 2nd relay in the box to have in cab control over the contactor


After more cursing for my decision to fit thicker cable i managed to fit and tighten the glands and close the lid!


Finally i managed to get it fitted and wired to the motor (not without a fight) as again my choice of thicker cables made my life somewhat difficult.



Routed the cables to my 2nd battery under the seat (no pics) and flipped the main switch and winch cab switch with my fingers crossed (that i do not melt anything!) So now its alive! all wired up and fully functional, Next and final post will be Synth Rope install picture.

Overall the kit i got for the contactor with wiring is a good buy, it came with 2 remotes and a wanderlead which has a twist and lock action., all packed in a water proof box. Time will tell if it will be reliable for the occasional use it will see.




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