Mark Posted May 4, 2006 Share Posted May 4, 2006 Just in case anyone was interested, I thought I would post up a few pix of the 8074 that I aquired at sodbury installed on my disco. When I bought the winch, it looked like this: It was bolted into a mount which also constituted the drum support. On closer inspection the motor was found to be burnt out, one of the solenoids was dead, and the wiring was generally shot. It was also missing the freespool lever. I stripped the whole thing down, and the internals were actually in pretty good shape. The motor that is installed now is on a borrow from a mate, and needed a new bearing pressing into the housing as the shaft was a lot smaller than my existing one. It also needed a small sleeve machining to reduce the id of the bearing even more, since I just bought the nearest easily available one that fitted the od on the housing! I have now aquired a new 5HP motor which will be going on this weekend hopefully... The freespool lever was missing, and having seen one or two pictures of these winches the original lever appears to be operated at the back of the winch. Given that I was burying this in the front of the disco I made my version use the same mounting points but be operated from the front. I am very pleased with how that came out: The drum end support was missing completely, so I started from scratch. I chose to use a proper ball bearing to mount the mainshaft in, so I got the biggest bearing I could find (the version with rubber seals on each side) and worked from that. I used a piece from a lump of aluminium I had lying around and machined a pocket to take the bearing. I also drilled and tapped mounting holes to mate up with the existing holes on the bumper. The aluminium is about 21mm thick and seems plenty man enough for this job. This is a bit of a carp photo, as you can't really see it once it is installed. I will take some better ones when I have it apart this weekend if anyone is interested: Mounting the beast once it was built up was a whole world of fun, mainly because the $crapiron bumper was not designed for a warn high profile winch. This meant some new holes needed to be drilled as this bolts through the front rather than through the base. I also had to remove some metal from both the back edge of the winch tray and from the underside of the slam panel to get the winch to fit in the hole! I deliberatly got a hawse with offset mounting holes knowing that the bumper was already drilled for an offset fairlead. Making my own drum support meant that I could utilise the existing hole. The winch looks pretty much at home in the front of the car, and does not stick out the front much at all, which is always good. It is a very tight fit in there though! I am running the winch off a second battery with an x-eng split charge to charge it. Installing the second battery was very easy, as it is pretty much a mirror image of how the main vehicle battery is installed. The only marginally complicated bit is the split charge relay, but since the second battery is on the same side of the engine as the alternator, cable runs are really pretty minimal. The wiring on the winch is all 35mm^2 flexible cable with crimped ends. I picked up a crimping tool on eBlag a while ago, and was very glad of it! The cable came from our local scrap metal place, so was very cheap! I can't remember where the terminals came from, but I have run out now so need to remember! Control for the winch is via a switch in the cab to enable it, and then either another dash mounted in-out switch or by plugging the remote into one of two sockets on the front grille (one each side). I didn't want to mount a switch directly on the front of the car, so the plug in remote works fine for me. This started out as a budget winch install, and whilst i has not been the cheapest way to do it, it certainly hasn't been the most expensive! All the machineing was done by me on my little myford ml7, which I find very satisfying. However, I must thank various members of the Horsham posse for putting up with me phoning them and dropping into thier workshops for impromtu winch lessons. Mainly this would be Nick (RogueVogue) for his patience and seemingly endless supply of bits of winch and Si (simonr) for the use of his press and generally putting up with me! Bit of a long post know but I figure I like reading this sort of stuff, so maybe a couple of other people might be interested too. Cheers Mark Quote Link to comment Share on other sites More sharing options...
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