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ground up build

 
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supermanotorious
Soul Rider
Soul Rider


Joined: 10 May 2010
Posts: 345
City: Phoenix

PostPosted: Sep 19, 2012 9:03 pm    Post subject: ground up build Reply with quote

The tools:


It begins as a 20' stick of 1 1/4" .083 square tube


The tube gets cut into several pieces, there are only 2 90 degree cuts so they get done first, then come the 45 degree cuts

a little 1/4" flat stock goes into as well


I'm waiting on parts (which I'll provide a comprehensive photo once they're here) so I decided to de-govern the Predator motor



lay the engine on it's side and remove the 7 side cover bolts (this is because there is some factory oil in the block that will run out if the engine is upright), the bolts will be replaced at 17 ft lbs

here is the governor arm on the outside of the block

here it is on the inside

unlike the 6.5HP engines, the governor is located on the side cover which makes for much easier removal


ok ok so there are a few more tools involved than I pictured but you'll get to see pictures of them too

I build 5 spool cross members into my winches where most use 6, they're totally sufficient and make me just a little more unique

what I'm creating here are the cross member shrouds, they serve 2 fold: protect the line from exposed threads on the bolt, and they keep the spool walls at a fixed distance from each other





an exclusive of Phoenix Winch, I weld all metal lock nuts inside the frame so bolts can be used as axles and wheels can be removed if necessary









I lay down the base pieces, clamp, and tack weld





once the base is complete I tack on

uprights:


forward arms:


splash guard and fairlead bar:


and finally supports:


made the motor mounts


test fitted an old starter battery


cut the axle to length (buy them long to make 2 for winches)


drilled the pillow block holes


the motor mount holes


and the bottom splash guard holes


got some more done today, picked up spool walls from wajerjet friend and assembled, then test fit and broke the chain, with spool in place I tacked welded the fairlead mounts
















sorry for an overdue post, its pretty typical in these builds that by the time I get to this point I feel like forget the camera, its balls out fabrication time

so I fabricated the battery tray, splash guard, and hitch mount, welded the hitch mount receivers to the frame as well as the fairlead mount and splash guard tabs

I got the sprocket, frame, and hitch mount painted and they look incredible, black is really the only color winches should be allowed to be

I'm going to give the paint plenty of time to cure then its time to assemble, spool the line, build the crate, and ship this bad boy to Cali, this build will tow riders up to 35 mph! (may not seem like much on the street but it's overkill for a wakeboarder unless he wanted to break a bus jumping record or try his hand at some barefoot skiing)

battery tray


splash guard (HDPE)








hitch mount receiver




hitch mount




assembled and shipped today! I work very slowly while assembling to avoid chipping or scratching the paint.

first- the wheels


fairlead



spool assembly


battery tray


motor mounts


motor


wire the electric start




put the chain on


the splash guard


rope and handle


pretty



ship


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supermanotorious
Soul Rider
Soul Rider


Joined: 10 May 2010
Posts: 345
City: Phoenix

PostPosted: Sep 28, 2012 1:05 pm    Post subject: Reply with quote




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GnarShredd
Wakeboarder.Commie
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Joined: 16 Jun 2009
Posts: 2310
City: St Pete.

PostPosted: Sep 28, 2012 1:14 pm    Post subject: Reply with quote

supermanotorious, That was one of my favorite parts of building my winch (the spooling via skateboard). Was the first chance you really get to see the thing come to life!
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3MileBayWaker
Soul Rider
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Joined: 14 Jan 2011
Posts: 256
City: Syracuse, NY

PostPosted: Sep 29, 2012 3:57 pm    Post subject: Reply with quote

Just out of curiosity, price of the exact same one? Many times this summer the lakes were too rough and I wished I had a winch.
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da Liks
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Joined: 22 Aug 2010
Posts: 594

PostPosted: Sep 29, 2012 11:59 pm    Post subject: Reply with quote

that is a straight up beauty!
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supermanotorious
Soul Rider
Soul Rider


Joined: 10 May 2010
Posts: 345
City: Phoenix

PostPosted: Oct 01, 2012 9:09 am    Post subject: Reply with quote

3MileBayWaker wrote:
Just out of curiosity, price of the exact same one? Many times this summer the lakes were too rough and I wished I had a winch.


thank you for your interest, that model, which includes engine, wheel kit, splash guard, and hitch mount upgrades is $1,655 plus shipping

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supermanotorious
Soul Rider
Soul Rider


Joined: 10 May 2010
Posts: 345
City: Phoenix

PostPosted: Oct 01, 2012 9:11 am    Post subject: Reply with quote

da Liks wrote:
that is a straight up beauty!


thank you

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3MileBayWaker
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Joined: 14 Jan 2011
Posts: 256
City: Syracuse, NY

PostPosted: Oct 02, 2012 2:58 am    Post subject: Reply with quote

Aight, thanks. Gotta save up some pennies now I have a number to get to Very Happy
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