Winch control box wires

[Mc4by]

Looking for solutions.
I have started the install of my winch and the control box cables are so short I have no good options for mounting it.
Where have you mounted your control box?
How do I extend the cables or do I just replace them with longer ones?

[GQtdauto]

Thick cables are better not joined , mine were plenty long enough but I put the control box on top of the winch on an angle, most hide them out of sight which may require using longer wires .

[jff45]

The solution I chose was to replace the thin 2 gauge cables with 0 gauge. Some people go to 00 gauge.

72773


I removed the solenoid and the controller plug from the controller box and mounted the solenoid alongside the battery where it's less impacted by the elements.

72774


I bought a rocker switch from Jaycar similar to the switch on the controller itself..

72775


I installed the controller plug and the additional rocker switch within reach under the steering wheel. Added small cutout switches to both to isolate them when not in use.

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I installed a bright LED beside the steering column to warn me if I've left either of them active.

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[Mc4by]

JFF45, what a detailed reply, thank you.
I will take my time and draw out a more comprehensive wiring solution based on your model.
How hard was it to crimp the 0 cable?\
I like the idea of running it from inside the cabin.

[MudRunnerTD]

JFF45, what a detailed reply, thank you.
I will take my time and draw out a more comprehensive wiring solution based on your model.
How hard was it to crimp the 0 cable?\
I like the idea of running it from inside the cabin.

You only need to run the large cable to the solenoid which I assume will be under the bonnet. Switching side can be small wires and this will make getting the wires into the cab easy.

I would suggest going to your local electrical supplier (middys or ideal or another) and ask them to make up your cables so they are crimped professionally if you don't have the right gear. Just mount the winch then figure out how far away your solenoid will be and using a piece of rope run through where you need the cables to go. Probably 4 @ 1m will give you enough options.

Note that I would recommend 35mm/sq cable or bigger. I run 70 to the highmount

[Winnie]

You only need to run the large cable to the solenoid which I assume will be under the bonnet. Switching side can be small wires and this will make getting the wires into the cab easy.

I would suggest going to your local electrical supplier (middys or ideal or another) and ask them to make up your cables so they are crimped professionally if you don't have the right gear. Just mount the winch then figure out how far away your solenoid will be and using a piece of rope run through where you need the cables to go. Probably 4 @ 1m will give you enough options.

Note that I would recommend 35mm/sq cable or bigger. I run 70 to the highmountThe suppliers won't crimp the cables, they will have all the pieces to make the cable but won't have the tools. Best to take a 6 pack and the parts to a local sparkie to get the job done.

Sent from my SM-G935F using Tapatalk

[Mc4by]

You only need to run the large cable to the solenoid which I assume will be under the bonnet. Switching side can be small wires and this will make getting the wires into the cab easy.

I would suggest going to your local electrical supplier (middys or ideal or another) and ask them to make up your cables so they are crimped professionally if you don't have the right gear. Just mount the winch then figure out how far away your solenoid will be and using a piece of rope run through where you need the cables to go. Probably 4 @ 1m will give you enough options.

Note that I would recommend 35mm/sq cable or bigger. I run 70 to the highmount

Great idea to have them made up. The cost of a big crimper for one job makes it cost effective to just pick them up done.

[jff45]

JFF45, what a detailed reply, thank you.
I will take my time and draw out a more comprehensive wiring solution based on your model.
How hard was it to crimp the 0 cable?\
I like the idea of running it from inside the cabin.

I bought a 16 ton hydraulic crimper from eBay. I see the 10 ton versions are now under $40. I don't know if you can get them all crimped for that price. There are at least 7 to do and you need to get them done properly.
I found Jaycar had the best price for the 50mm connectors.

Make sure you have the lengths spot on before you get them done.

The thin wires between the solenoid and the the controller plug in the cab are easy to pass through the firewall.

[Mc4by]

Cheers JFF, I will look into a crimper at that price.

[jff45]

Just a tip if you do your own.. When I did the first one, I then soldered (tinned) the opening as a barrier against corrosion but found that the solder had wicked through the crimp. This is to be avoided because it removes the flexibility of the copper cable after the connector and becomes a possible fracture point.
The solution I found to get a proper gas-tight crimp was to redo the crimp with the 35mm dies after the initial crimping with 50mm.
I'm not sure the local auto electrician will bother doing that for a $10 6 pack :) (Disclaimer: I don't drink so I really have no idea what a 6 pack costs)

This is the result I got before applying the heatshrink..

Those are 50-8 connectors from Jaycar which don't have the flared entry but that's easy to do with a conical centre punch.

72795

[MudRunnerTD]

A couple of threads worth visiting if your going to buy a Crimper. I also have the $45 Crimper off ebay and they are a winner.

http://www.nissanpatrol.com.au/forums/showthread.php?39052-How-to-fit-large-battery-winch-cables-into-crimp-ends&highlight=crimper

This is a very good thread regarding the crimpers etc.

http://www.nissanpatrol.com.au/forums/showthread.php?34688-Crimping-tool&highlight=crimper

[jff45]

Yes, I think it's worth buying one for the price they are now. I've also made earth straps with mine and remade the main starter cable when I did my conversion.

[waynet]

Hi Scott, I bought an Aldi winch. I replaced the solenoids with a heavy duty controller. I mounted the winch with the controller box inside my bullbar. I made up my own leads with 2/0 cable and crimped the lugs with a nail punch and then ran solder into the wires. There is no way this will come undone. I mounted the socket for the hand control in the engine bay so it cannot be accessed without opening the bonnet which is alarmed. I leave the power cable to the winch disconnected from the battery terminal (I bolt it to the top of the battery clamp) and only connect it when I want to use the winch. This prevents driving with a live wire in the front of the vehicle and ensures the winch has no power going to it. This setup has done everything I have asked of it on many occasions.