My latest small project ..

Saw an ad on ebay, "Winch, 24v, large, broken" cheeky bid and won it for a tenner!! Very local to me so picked it up, though when I say picked it up I couldn't be sure this wasn't what threw me back out!! Damned heavy .. full of steel wire rope ... The gearbox is effin' huge.

Any road up it turned out to be a Kingone (Goodwinch) TDS 16.5c with broken motor and gearbox end plates. Checked Goodwinch, got a list of parts ordered, delivered and just fixed it all up.

The winch is brand new inside, but looks to be knocked about outside!!

More pics of the strip, rebuild etc to follow, but this is how it stands right now ..

It won't fit the existing bumper space, so I'm gonna build a new bumper .. 10mm plate for the winch and bumper mount, 2x2 x 5mm square section tube and 1x1 3mm to connect it all together, with 6mm plate, maybe, to fill the bits in ..

So the 'fit the monster winch' project moves on .. I is making a noo bumper ..

Once again it'll be a fluidly managed project .... making it up as I go along.

10mm plate should be big enough .. so an hour of measuring, marking out, re-measuring, checking the ruler and measurements, then centre popping the holes prior to drilling ... This pic shows the base plate just bolted on at the standard bumper mount holes.

Then taken off to properly measure and mark out for the eight mounting holes .. it's a big winch ...


It all fits fine, so drill the winch mounting holes ...



They needed to be drilled out to 13mm, the tiny pillar drill I have wasn't man enough to drill a larger hole than 10mm, though it does up to that dead easy, which I did in a couple of steps, 4mm 7mm 10mm .. so I tried with the Hitachi battery drill I have and job's a good 'un ..

The solenoid pack will be moved to better suit the winch.



The winch is a Kingone/Goodwinch TDS 16.5, so serious pulling power, which is often more what we need than speed .. hence the eight bolts holding it to the baseplate ... The bumper will now be built around the winch and tied into the chassis, not just the front legs, as I see fit and all triangulated etc. All the bolts are 8.8 grade minimum, the chassis mounting bolts are 12.9 heads with harder nuts and spreader plates both sides, again all plates made by me so probably over engineered ..

Most of the bumper will use 6mm plate gussets, with 50x50x3mm wall square tube and 25x25x2.5 sq tube for incidental bits .. it'll not be a standard looking bumper, but more like a triangulated gantry ... and hopefully pretty strong ...

Look forward to seeing how this goes @Paul D , Looks like it will be a monster , did you think about recessing it in towards the rad a bot more to reduce the profile?

I keep considering getting a winch and bumper, but I will probably get off the shelf, Rhino / Winchmax 13500 and an Ian Dixon low profile bumper.

Cheers

neilly said:

Look forward to seeing how this goes @Paul D , Looks like it will be a monster , did you think about recessing it in towards the rad a bot more to reduce the profile?

I keep considering getting a winch and bumper, but I will probably get off the shelf, Rhino / Winchmax 13500 and an Ian Dixon low profile bumper.

Cheers

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It already is further back than the small Warn I have, such that the grill won't go on atall, so I'll just make a grill from perforated sheet, I guess. It measures exactly the same as the bumper I just took off and the only thing that'll project further forward is the Hawse..... But it's much higher too, now, so will also give better approach angle. Wins all round...

Paul D said:

Wins all round...

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Nice............Now all you have to do is find something really stuck to pull out...........Are the trees safe around your way???...LOL.

Cheers

I aim to stop the earth spinning ..

Seriously, some of the mudholes in the Forestry we go into are deadly. Last time there, four of us, took about 8 hours to go 4 miles! Small winches, slow pulls, with stops to stop them overheating! At one point we were so nackered we had the four Landys connected by the winch ropes. First one sets of winching or driving as they can, connected to second which is freespooling out. First one goes as far as he can, then second sets off, winching off the front one, connected to the third which freespools out. When second gets up to first, third sets off winching/driving as he could, with me connected and freespooling mine out so I can then drive/winch to catch 'em all up and start off again, like some freaky Caterpillar. We had wives with us who really weren't up to the strain, it was supposed to be a nice day out and dry. It wasn't ... )

Few extra bits ...

Initial marking up and setting out. Very little actual measurement, it's just made to fit ... These first bits are being made upside down, with any luck they'll fit when I turn it back over ...

The ends will, when it's all welded together, have the ends straightened and an end cap fitted.



Gonna be a couple of sooper sekrit bits on it to stop mongrels pinching the winch, a hint of which is in the last pic ... though if they do get it off they'll likely get a feckin' hernia anyway!!

Hopefully the bumper will look nice and slim and be immensely strong. I'm not going to rely on just welds for parts, I want to be able to take the winch and it's baseplate out, separately to the bumper base mainly due to almost needing a winch to move it at all. If it works that's fine, if it doesn't I'll just weld it all together!!

Plodding on, slow and steady ..

Nothing bolted up yet, but the bits as they are fitted together 'lock' onto the chassis without nuts on the bolts. I didn't try it with the weight of the winch mind!

What finish you going to give it Paul?

Cheers

Dunno yet, probably just primer and matt black. I'd like to try a chemical black but not sure how well it's last ... and paint can just be touched up!

I think it looks fabulous. If you find my car in the same car park as you, can you please stay as far away as possible.from me with that monstrous bumper?

Heh, had to go out, so took the gubbins off ... quite like it like this, all naked ...

So, no pics from today, but more feckin' about ...

If you see the pics above there's one bent sq tube at the back and one at the front, below the winch plate. Bolting stuff together to see what fits, how it works etc, I've now swapped the front tube from below to on top of the winch plate. This will increase ploughing height, so less of it hopefully, but is also easier to make secure. I've also made up some lower mounting plates that need to be bent, propane torch, vice, 'ammer, can't see anything wrong with that plan then ...

Took my Warn, 12V, motor off, to check it .. hmmm ... water ingress, rust and dirt and not quite rolling freely bearings ....
Took the TDS, 24V, motor off, shiny new looking .... hmmmmmmmm

So, some cleaning & fettling of my Warn motor needed. However, the wife (gordblessercottonsox) has suggested that maybe a new motor would be a good idea .. and she might pay for it!!! Dreams might come true .. well, some of 'em ... So, Red Winch Oxmotor may be on the cards ...

Hopefully the TDS won't let anywhere near as much water in as the Warn in future .. Pics tomorrow when it's light again.

And a new winch rope turned up ... 12mm 30m, with big yellow hook, yellow Plasma, slightly shop soiled £150 down from £300+ bargain ..

Oh, and finally it steers straight. Front steering rod has been too long for a while, so pulling to the left slightly but I just drove with it. Well, today I fixed it .. Still needs a little more adjustment, but goes straight now for at least 50m ..

Happy. Oily, dirty and nackered, but happy ..

Latest pictures ..

Moved a few things around, added some and still some to add. I need to cap the ends, ran out of welding wire and despite Screwfix saying it'd be here 'next day', yesterday, they actually meant 'next working day' ie tomorrow! So, fettling a few things, like working out how to fit the hawse, maybe a front plate bolted to either the winch or welded to the front bar. I'll also have an A-bar of some sort eventually.

New winch rope, shop soiled, 12mm Plasma, down to £150 so a bargain I couldn't resist.

looking good, you going to fill the top and bottom outboards ends with triangular plates?

How are you bolting it in, Assume the 4 std bolts on the dumbbells, are you using any bolts further back in the "jate" bolt holes?

Cheers

Yes, only quite thin section, whatever's in the shed, they're only aesthetic really, and yes .. Still working it out but there's gonna be an extra plate each side to bolt further back on the chassis. Trouble is only getting a couple of hours every couple of days to work on it means all the tools and stuff need packing away and getting out each time 'cos it's never just welding or just cutting/grinding, I seem to use everything every time, I really need a lockup or garage ...

This is effectively it. I can't believe the times I've back-pedalled doing this just through things breaking or just plain bad weather ...

Decided, mostly due to the weight ramping up every time I added a bit of metal, that I'd keep it simple, very simple. Still got the chassis side plates to weld on and fit, but this is exactly how it will look like as they won't be seen. I might not even put them on as it'll really only be pulling similar weights as the previous winch held by the same fixing points. In reality I know I will, I prefer extra capacity .. I've also still to weld on any recovery rings, but a mate who builds HGV trailers says he'll get me a couple of weld-on D-rings, so they'll go on when I get them.

Managed to paint it quickly yesterday, plain grey primer and black paint, and built it back onto the chassis, so wiring up today and feeding the new rope on. I've made the grille fit (in two parts, only one in the pictures) but as I came to wind the winch in to pack the rope on initially a bloody connector on the Allbright broke! Couldn't write it in a script. So, took the Allbright apart and think I can fix it, the pic shows it with the bottom cover off, but in the meantime our lass just said order a new one!! (I'll still play with the broke one ..

The alloy plate above the winch motor in the pics is where the Allbright and winch remote receiver go, high enough to not get too bothered by water I hope.

Looking good Paul,

Very nice work , as you say clean and simple............also looks like it will clean off easily when dunked in the filthy stuff.

Something I was looking at when I fitted mine the other week, what bolts are you using? I currently have 6 off M10 x 1.5 bolts holding the bumper to the chassis, 8.8 grade. and 4 off 10.9 grade m10 x 1.5mm bolts holding the winch to the bumper , which I am going to change to 12.9 in the future.

Cheers

Currently 4 M10 Allen head 12.9 bolts for the winch-plate to chassis, but when I weld the 'wings' on that'll be another two, but across the chassis, too. 8 M12 8.8 grade bolts for the winch to the winch plate! They're what came as the winch mounting kit, with another 2 for if I need to add a strengthening plate across the top of the winch, but I don't think that'll be necessary. Really pleased with it as the bolts hold the bumper on, with the winch, without drooping, without nuts on, so at least I marked and drilled it out reasonably!

Having some thoughts about the 12.9 grade and wondering if they aren't 'too' strong. Sounds odd but I think they are great in tension, but not so much in shear strength. Having said that, the standards are 10.9 grade so it isn't much difference in reality, so long as they're tightened up a lot. Mind, 12.9 still shear at a higher strength than 10.9 or 8.8, so on balance I'll probably leave them ...

(Edit) Actually, I'm not so sure what the standard chassis to bumper bolt grade is, I now suspect they might be 8.8 ... The ones I have in 'the box', I presume originals as they are pretty nackered, have 8.8 on the heads ..

Paul D said:

(Edit) Actually, I'm not so sure what the standard chassis to bumper bolt grade is, I now suspect they might be 8.8 ... The ones I have in 'the box', I presume originals as they are pretty nackered, have 8.8 on the heads ..

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Thanks, Yeah, my std bumper to chassis bolts are 8.8 at the moment, 4 off where the std bumper bolts to the dumb iron and 2 off down underneath in the jate tubes. I am going to change to 10.9 on these 6 unless I can get 12.9 from the local bearing traders tomorrow ( missed that out in the earlier post ),

Interestingly the bolts I took off the the winch to bumper fitting points were SS A2 70 , so those have been discarded in the short term for 10.9 M10, but will be changed for 12.9 this week.

Cheers