My winch has sclerosis of the windings

My winch has sclerosis of the windings, yep its had way too many drinks and has given up.
Its a warn XD9000CE about 6 years old and abused, never been serviced so its no ones fault but its irresponsible owner.
Done lots of watercrossings and was very corroded inside, I did decide to service it as the brake didnt work which is a bugger when you stop winching on a hill as it just unwound and back down we would go.
I also had it upside down so the drain holes would only let water in and not let it out, another bugger. Only worked that out when I pulled it apart.
So being a eBay serial pest I bought a flash new XP9.5 for a song, you beauty.
Loosened the bar off and wedged it forward, connected the cables to the new purchase and went to bolt it in place to find to my dismay it is 20mm longer in the go end, meaning motor, and it would not squeeze between the chassis rails, another bugger.
So what to do?, thought about cutting the mount plates out of the bar and shifting them left 25mm. I am able to do stuff like that but I am also very lazy. The thought of dewiring the UHF antenna lights etc was all too much.
After a nights sleep and allowing the TED's to wear off I came up with a plan.
I'll get one of those cradle thingys, none on eBay, another bugger.
Oh well we have internet for a reason. Warn has them for $290.00 shiezen howzen, and the bloke on the phone said the front bracket socket adaptor are for the back even though its called a front adaptor thingy, and that was another $179.00.
http://www.4by4connection.com/wapowimo.html
TigerzII has them, the cradle, delivered for $80.00.
http://www.tigerz11.com.au/detachable_winch_hitch.html
He has made a blue but assured me he was right and he was. But they didnt have the bit to bolt onto Mactrol.
No worries I can make that.
So a bit of steel 720mm long and $30.00 joins the chassis rails and with bits of scrap around here I made the front 50x50 adaptor like a tow hitch. Looks flash too with a Warn sticker on its new black paint job.
The winch fits and works a treat plugged into the anderson that was there for the stuffed one.
Very happy.
Will now make up an 12VDC extension lead so I can hang it off the towbar and pull those other makes up where Mactrol has gone :Yahoo!:
Macca

So how was it all done? As a DIY project I'll do my best to give you an idea how to do it, this looks like it will work fine but I havn't tested it or had any engineering imput.

Materials
65x65x6mm square pipe 1 off x720mm 1 off x150mm
40x8 flat bar 1 off x150mm
M10x40mm high tensile bolts & nuts with flats spring & washers 2 off
Tools
Welder capable of welding 6mm or a friend with one
Drill & 10mm & 16mm bits
Grinder
Hacksaw or cut off saw
Sockets tapemeasure square etc to do the work

I removed the two 12mm bolts that screw down on the top of each chassis rail, on a OEM steel bar these have a slot that locates the bar to the vehicle.
Accurately measure the distance centre to centre
The long bit of 65x65 has the ends cut at 45degrees and has a 12.5mm hole drilled at each end at the above measurement.
Now you can bolt this in place tight.
The 150mm piece will become the hitch reciever part and needs to have a 16mm hole drilled through it to accommadate the pin.
The hitch reciever part now goes through the hole where the fairlead used to sit, I had to grind a bit of steel away to get it to fit through. But it against the long piece you have just bolted in. Square it all up and tack it in place. To get it level it does not sit flush at the "T" joint just a little lower.

A couple of tips;
Disconnect ALL vehicle batteries as weld amps will fry your electronics. Disconnecting the batteries "opens" the electrical circuits so amps cannot flow therefor no damage can be done.
Keep all flamables away and have some fire protection available, extinguisher or hose.

Bolt the piece of 40x8 bar in the 2 slotted holes above the fairlead hole, you may need to file them out a bit bigger.
make sure it sits on top of the hitch reciever part and tack in place.
Fit the winch cradle making sure there is clearance enought to make it all work, if you are happy with all this weld it solid.
I welded it in situ, but you can remove the bull bar and take it out to do it on the bench which is alot easier to get good welds.
Paint it and put it all back togeather and away you go.

http://i254.photobucket.com/albums/h...n/IMG_3230.jpg
http://i254.photobucket.com/albums/h...n/IMG_3231.jpg
http://i254.photobucket.com/albums/h...n/IMG_3233.jpg
http://i254.photobucket.com/albums/h...n/IMG_3234.jpg

Now you can fit a tow bar for easy parking of your trailer or caravan. Also the hitch recovery point will fit there as well. (not certified weld so wouldntuse it for a snatch recovery)
Happy building

Macca

Selecting the winch, I like Warn as they have been around for a while.
There are plenty of other brands that have been on the market for a while as well and lots of new untested or knockoffs out there as well.
Bought a mag that did a fairly comprehensive test, the warn came third due to its price.
It was the best winch tested so it said in the article, it pulled faster, used less amps, kept water out the best and ran as long as 2 others with out fail and was engineered to do what it said.
It was a no brainer for me as parts should be readily availabe across the country (the reason I own a Patrol)
Less amps means its not draining the battery as fast, some used twice the power.
Was dissapointed the mag rated it 3rd, it was the best winch by far. Its up to the consumer if they want to part with the cabbage.
Thats what they do, probably sponsor driven results, I don't know.
Anyway enough of that, I hope to get out and give it a bit of a go soon.
It's been bucketing down here for 3 days so the tracks will be slipery for next weekend.
Macca

Nice work macca....... now all I need to do is learn how to weld..... hehe.

Took some pics today, they might explain what I'm waffling about :smile:

http://i254.photobucket.com/albums/h...h_IMG_3230.jpg
http://i254.photobucket.com/albums/h...h_IMG_3231.jpg
http://i254.photobucket.com/albums/h...h_IMG_3233.jpg

Macca

Very nicely done Macca,
I like the way it gives you all those options you don't get with a solid mounted
winch up front.
Got me thinking now!

So sorry Plasnart just saw your question this morning.
That pine tray it is sitting in fits in the pod in an 20x20 alum angle frame with a ratchet strop holding it in place, its at the back door for easy access.
It is plenty wieghty, will get the batroom scales and wiegh it - not so sure I need to know....
Wasn't really game to reshape the bar but after the trailer build I feel confident to do it now, it stays at home when not needed so has to help with fuel economy and suspension fatigue.
Macca

top idea Macca
well done