Want to build my own winch

Jpage · Newbie Joined: 01 Apr 2012 Posts: 16

I am looking to build my own winch and need some input on what i should use and what works to gather. i want to do it on somewhat of a budget

I am basically looking for a part list i know i need:
Frame
Motor
Spool

What else??

I mostly need help on gearing/clutchs , i am thinking about using a motor from harbor freight 346cc maybe the 212cc , thoughts?

GnarShredd · Posted: Apr 02, 2012 5:50 am Post subject:

In addition to what you listed, you'll need the following, much of which I found at Northern Tool & Equipment or on eBay for cheaper:

-Pillow Block Bearings - (to mount the spool on the frame, make sure to get the right size for whatever axle you get)
-Torque Converter - aka "TAV", comes with a drive sprocket on it, either a 10-tooth or 12-tooth, make sure to pay attention to which one you get. You can also get a centrifugal clutch for much cheaper but I don't recommend them myself. They're tough on the machine and on the rider's arms/shoulders.
-Axle - To mount the spool to the bearings. I picked up a keyed go-cart axle, made it really easy to mount things on for a good fit.
-Sprocket - for the spool, you can find these in the go-kart section of northern tool
-Sprocket Mount Hub- needed to put the sprocket on the axle
-Chain - make sure the size matches the large sprocket & torque converter
-Motor Mount - Built in to the frame, I'd recommend cutting slots in the plate instead of just holes so you can slide the motor and put tension on the chain. Also, use a hard rubber of some kind in between the plate and the motor to reduce vibration and provide friction so the motor doesn't slide once you crank it in to place.
-Roller Fairlead- Mounted on the front of the frame to guide the rope on to the spool. kind of expensive at stores but you can find for CHEAP online.

I think that's everything. I'll check it over again once I wake up a bit more to make sure I didn't skip anything.

The basic rule people go with on gearing with a torque converter is 6:1 (so if the TAV is a 10-tooth you need a 60 tooth sprocket on the spool, if it's 12-tooth you need a 72). With that said, there's a LOT of trial and error that you'll need to go through to get it working just right. Every motor is a little different and you have to take spool diameter size in to consideration. For example, My winch has a 12-tooth sprocket on the TAV, 72 tooth on the spool, and a 7" spool diameter. I recommend making the spool adjustable with holes at 6", 7", and 8" so you can play around with it a bit along with the gears and dial it in just right.

For reference in finding a motor, I've got an 8HP and it can deep water start me at 220lbs. If you're going with a bigger motor (above 6.5HP), I recommend trying to find a Torque Converter that will fit a #40 or #41 chain. Many of them are made for #35 chains and while they'll work, the #40/#41 chain is much heftier and you won't have to worry about it breaking (I've seen #35's break a few times, no fun when you've just lugged your winch down a big hill to a spot only to have to take it right back up).

onecrazyredhead · Criminal Joined: 04 Feb 2012 Posts: 56 City: Lusby

Www.wakeboard-winch.com check it out.

Jpage · Newbie Joined: 01 Apr 2012 Posts: 16

Thanks for all the input i got my parts list figured out. Now just need to decide on a frame style, steel or aluminum

GnarShredd · Posted: Apr 04, 2012 5:10 am Post subject:

Jpage, If you can afford aluminum I'd do that (for the spool walls too). Save weight anywhere you can. My winch is a BEAST and while I love how it looks and the fact that I made it myself from scratch, I really want to upgrade to an aluminum frame as soon as I can afford to.

Jpage · Newbie Joined: 01 Apr 2012 Posts: 16

What size spool do i need to fit around 2,000 feet of line MAX. 15"?

Also what torque converter for a 13hp motor?
I was looking at the TAV2 do i need the 40 series?

GnarShredd · Posted: Apr 05, 2012 5:27 am Post subject:

I forget what the rope I used is called but it's pencil thin. You can probably get away with a spool that's 10" wide, maybe less. I'll have to measure when I get home but I think mine is 12" wide and is a little too big.

Not sure of the difference between the 30 and 40 series. I think I have a 30 on my 8hp and it runs great. Just check for the HP rating and you'll be ok.

Jpage · Newbie Joined: 01 Apr 2012 Posts: 16

I figure 9" wide but what about the diameter of the spool side?

GnarShredd · Posted: Apr 06, 2012 5:15 am Post subject:

Jpage, Not that tall. I'd say 10". That way you can adjust the inner diameter anywhere between 6-8in. and still be ok, 12" if you wanna be safe.

onecrazyredhead · Criminal Joined: 04 Feb 2012 Posts: 56 City: Lusby

buy the spool! quick release is a must have!!!!

Jpage · Newbie Joined: 01 Apr 2012 Posts: 16

onecrazyredhead. where can you find the spool quick release at??

onecrazyredhead · Criminal Joined: 04 Feb 2012 Posts: 56 City: Lusby

http://www.google.com/url?sa=t&rct=j&q=wakeboard%20winches&source=productsearch&cd=4&docid=3740627115835299629&ved=0CJcBEIMIMAM&url=http%3A%2F%2Fwww.krypt-wakeboard-towers.com%2Fservlet%2Fthe-49%2FReleasing-Wakeboard-Winch-Spool%2FDetail&ei=9umAT5vOHcSD0QGhv5yBCA&usg=AFQjCNE_yqVVzR337AMQnq9p44tK8sgQIw&cad=rja

Jpage · Newbie Joined: 01 Apr 2012 Posts: 16

at that cost its not even worth it. if you have your motor and sprocket lined up properly it should un spool just fine, if it free spins you could get a birds nest a little tension is nice. 224 bucks? i think mine is going to run me around 80 or 90.

onecrazyredhead · Criminal Joined: 04 Feb 2012 Posts: 56 City: Lusby

i telling you a good spool is worth it. sometimes cheap is not the best answer!

GnarShredd · Posted: Apr 09, 2012 12:28 pm Post subject:

Jpage, I love having a releasing spool but I made mine. The one onecrazyredhead linked is insanely nice (I've seen a winch with one, was awesome), it is REALLY expensive and you can build something that's work just as well.

The pain in not having a free-spinning spool is two-fold. One is that you get worn out pretty quickly if you're doing a full-day of winching. Two is that it seems like it can wear out the belts on the torque converter. If you'd like I can take some photos of mine for reference to give you an idea. There's some changes I'd make on the next one I build, but it works pretty well now.

Jpage · Newbie Joined: 01 Apr 2012 Posts: 16

Gnar Shredd that would be great if i could see some pictures of yours! maybe even a parts list too!

onecrazyredhead · Criminal Joined: 04 Feb 2012 Posts: 56 City: Lusby

Check out wakeboard- winch.com my winch is on there! Same name too. All ur info is there

GnarShredd · Posted: Apr 10, 2012 6:26 am Post subject:

onecrazyredhead, That's the wrong link. are you thinking

http://www.wakeboarding-winch.com/

Jpage, here's a thread where I posted a few pics but nothing detailed at all and you definitely can't see the spool design in any detail. I'll try to take some better shots for you.

http://forums.wakeboarder.com/viewtopic.php?p=1262936&sid=79af3d75c4d48af8b559c6f1219dc8f0

Jpage · Newbie Joined: 01 Apr 2012 Posts: 16

here is my build plan, how does the frame look, its 1,5" .125 wall and 2.5" .25wall

supermanotorious · Soul Rider Joined: 10 May 2010 Posts: 345 City: Phoenix

you're welcome to use my frame

Jpage · Newbie Joined: 01 Apr 2012 Posts: 16

kartman · Posted: Apr 15, 2012 7:40 am Post subject:

holy cow! .250 wall?!?!?!?! .095 and .065 is plenty thick. the size of your frame is going to be HUGE!

or you can use a phoenix frame, or i can build you a villan winch frame.

Jpage · Newbie Joined: 01 Apr 2012 Posts: 16

the .25 wall is for the hitch mounts to give it a 2" ID

The total weight of the frame would be 20 lbs