DB's Cage Canopy Build

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Re: DB's WARNING Winch Rebuild

Postby DeadlyBeast on Thu, 28 Dec 2017 10:12 +0000

Critter350 wrote:That’s looking the goods DB, should last forever.
CheersCrit

I'd like to think it would Crit. It will wear out a little bit slower than warn intends at least
Got some time today to reassemble

Most of the fastening hardware showed signs of rusting or corroding
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Prepped for a coat of rust guard
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Lots of different websites and youtube clip all give different recommendations for what grease to use.
After breaking the winch down it appears that Warn use 4 different lubricants:
A CV like grease in the gears, a red light grease or oil in the bottom sun gear that inserts into the brass bush, a thick brown grease for the free spool gear and the green grease for the seals.
XP grease was a bit thinner than the original green grease but perhaps it had hardened over time
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Packed in to just above the level observed when torn down
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Reused gaskets on the gear housing - still in very good condition compared to the motor housing gaskets
Reassembled housing using match mark
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Used XP grease on the gear lever
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Trial fit of the winch drum to access grease. It didnt hold shape like original grease
Had a about 20% too much packed in but easily cleaned up
Applied a light smear of XP grease onto the face of the top sun gear
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Temporary installation of OEM spreader bars. Checked correct seating of motor spline
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Remembered to Install the motor end washer but forgot the motor spline hub
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Fiddly spreading the bushes out over the bearing and commutator
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New gasket on the motor. Dielectric grease on terminal bolts
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Was easier to put the gasket on the end plate - held its own position
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More corrosion under the earth terminal. Cleaned up with dremmel, new 316 stainless washer and dielectric grease
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Had to sand off the paint in the motor end cap where the bearing seats - snug fit
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Easier to install the motor horizontally.
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Re: DB's WARNING Winch Rebuild

Postby martynvella on Fri, 29 Dec 2017 5:05 +0000

shit I hate that, just spent half an hour writing a reply to your post to get cant display page error when I hit submit, now I remember why I don't bother.
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Re: DB's WARNING Winch Rebuild

Postby Critter350 on Fri, 29 Dec 2017 7:48 +0000

Reckon you need to replace the ‘Warn’ stickers with ‘DeadlyBeast’.


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Re: DB's WARNING Winch Rebuild

Postby DeadlyBeast on Fri, 29 Dec 2017 8:03 +0000

martynvella wrote:shit I hate that, just spent half an hour writing a reply to your post to get cant display page error when I hit submit, now I remember why I don't bother.

I've done that plenty of times too. Sometimes hitting the back page brings the text back, sometimes not :x
I took photos of re-greasing the gears but lost the images somewhere???
Hope you are able to share your knowledge in any case

I plan to strip it back down in a year an see how its holding up. I know I could have done things better and dont expect it to be looking good as new when reopened. All winch brands need regular maintenance - I left mine too long.
I can see why it would cost a lot of money to pay someone to repair a winch.
Perhaps with Marty's input I can make a winch refurb thread in a years time to help others out so they dont go making the same errors I made

I reckon I'll just remove the stickers Crit :lol:
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Re: DB's WARN Winch Rebuild

Postby martynvella on Fri, 29 Dec 2017 10:46 +0000

Ill give you the shortened version.....I hope.

Only one thing id have done that you didn't is give the armature a good soak in the same paint you did the coils with and baked it just incase there is any flaws in the original varnish, oh and gave the bearing housing surfaces a smear of grease before painting, paint just wipes off then. Cant remember if you did or not, plenty of never seize on every thread.

Repairing these days is out of the question because of labour costs, cheaper to just buy another one unless you do it yourself, much the same as everything these days, only advantage is that you know it has been done by a tradie and not a production line in a third world country somewhere. In a well equipped A/E workshop it would have taken at least half a day if not more to do what you did after you have done 3 or 4, lot of money to pay for an inspection and clean up, very few would think it worth while at around $100 an hour.

Once a winch has been pushed to destruction they are very rarely salvageable economically, new motor sections are available but only works if a throughbolt isn't welded in the thread and snaps off.

Good work by the way.
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Re: DB's WARN Winch Rebuild

Postby DeadlyBeast on Sat, 30 Dec 2017 9:14 +0000

Cheers Martyn
The armature looked good - one of the few things in the motor housing without rust. I'll be pulling it down again in 12 months or so so will give it a coat of urethane. I'll put some coppereaze on the motor end bolts before mounting it again.

I used a recovery program to retrieve the lost gear images that I inadvertently deleted off the camera.
The gear end is fully sealed - no water ingress at all evident

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Also recovered a couple of pics of the breather install.
I left the bottom drain hole open in the motor housing where some attempt to completely seal.
Leaving that open due to the hot climate and high probability of condensation formation.
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Tapped a 3/8 BSP thread, installed a 6mm push to fit air fitting.
Ideally it would be on the top of the housing but not a practical location for access
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This will serve as a breather and an air line connection point from the compressor to blow out any moisture.
The compressor could also be activated with an airline connected during water crossings.
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Re: DB's WARN Winch Rebuild

Postby andy666 on Thu, 04 Jan 2018 3:39 +0000

If you are going to connect an air compressor to the housing, just make sure you have a low flow compressor or a big enough drain hole. If the drain hole isn’t big enough the housing will still build up pressure and blow the seals out, or worse crack the housing.
Maybe test the compressor and drain hole size on a coke bottle first.
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Re: DB's WARN Winch Rebuild

Postby martynvella on Thu, 04 Jan 2018 4:40 +0000

A dryer in line maybe. Compressors pump in water vapour too which will condense in the winch.
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Re: DB's WARN Winch Rebuild

Postby DeadlyBeast on Thu, 04 Jan 2018 4:52 +0000

Thanks Andy. I had considered pressure but not in great depth.

Not wanting to overthink this too much with dynamic air pressure formula my thinking is...
The air line internal diameter is a smidge under 4mm giving about 12.5mm2 entry area
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The drain hole is 2mm x 8mm / 16m2 exit area
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The motor housing is about 7mm thick steel
Compressor under no load (0 PSI) produces 174L per minute

If the exit hole is larger than the entry minimal pressure could build up ... I think if its vented little or no pressure build up.
Even if the exit hole was smaller, and as the motor casing is rigid, I imagine the air would just escape at a higher velocity than at entry?
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Re: DB's Cage Canopy Build

Postby DeadlyBeast on Thu, 14 Jun 2018 7:52 +0000

Decided to forgo the flexibility of an open tub and build a canvas canopy cage.
Need a bit more room for touring than the tonneau cover provides and add some full time accessories/tools etc.

A rough draft below - still figuring out how to use sketchup. Anyone know how to make joins seamless?
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Will have the ability to attach roof rack and RTT, Air vents at front to reduce rear dust ingress, piano hinges ....
Yet to decide on either single folding T handles for each door a two thumb compression locks
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Plan to build main supporting frame out of 30x3mm RHS
Cage doors and non-supporting ribs from 25x2mm
Will have to send away for RHS bends

Plan to wrap in Marine Hood liner
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DB's Cage Canopy Build

Postby Critter350 on Fri, 15 Jun 2018 5:58 +0000

Looking forward to seeing this one being built.
I haven’t use sketchup much since Google sold it to Trimble, don’t remember anymore.
Can you just delete the line / seem?


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Re: DB's Cage Canopy Build

Postby DeadlyBeast on Fri, 15 Jun 2018 6:41 +0000

Critter350 wrote:Looking forward to seeing this one being built.
I haven’t use sketchup much since Google sold it to Trimble, don’t remember anymore.
Can you just delete the line / seem?

Ha! me too :lol: Cigweld 185 3-in-1 ordered earlier this week - wonder how long thats gonna take to get to get here
Didn't realise ketchup was a google program - there you go, this forum keeps giving

Wish it was as easy as that. I drafted the left side only to cut the button pushing time in half.
Thought I could just copy, paste, flip, join.... yes I could but, apparently not seamlessly.
When I try to delete the seam line it deletes the entire draft or one side
I'll figure it out
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Re: DB's Cage Canopy Build

Postby DeadlyBeast on Sat, 16 Jun 2018 8:22 +0000

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Potential (likely) issue... when the canvas goes on the zips at the back will not go up far enough to allow the rear door to open. With present back door design the zips will have to go all the way up to the roof and maybe over to allow the door to open.
Trimmer would prefer 50mm between hinge and top of roof - zips will go 50mm up past the hinges sides of doors
May have to add an extra 30mm RHS below the top bar to pack it down
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Re: DB's Cage Canopy Build

Postby Critter350 on Sat, 16 Jun 2018 10:15 +0000

Sketchup- you grouped that one side before you copied and spun it around? Did you explode it again to just delete the one element (line)?


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Re: DB's Cage Canopy Build

Postby DeadlyBeast on Sun, 17 Jun 2018 7:12 +0000

Yeah mate
Too much grouping - not enough time spent on tutorials.
My model was full of messy errors.
I got frustrated with the time I was wasting clunking around so I got onto the sketchup community forum.
A brilliant, experienced and very helpful member cleaned it all up and redrafted it for me
The power of online collaboration and ability to share skills and transfer knowledge from half way around the world! 8-)

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Re: DB's Cage Canopy Build

Postby Caleebra on Tue, 19 Jun 2018 4:34 +0000

Thats pretty amazing, I've used Sketchup for a long time, but not gone as far to achieve the skills for the detail as the model you've got there! :o
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Re: DB's Cage Canopy Build

Postby DeadlyBeast on Wed, 20 Jun 2018 8:10 +0000

Caleebra wrote:Thats pretty amazing, I've used Sketchup for a long time, but not gone as far to achieve the skills for the detail as the model you've got there! :o


Thanks Arne but I can only take credit for the cage design...which is about to change :lol:
I downloaded the hilux from sketchup 3D warehouse and just tinkered around with it.
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Re: DB's Cage Canopy Build

Postby Caleebra on Fri, 22 Jun 2018 5:49 +0000

Which model did you download? The one i used in my build for the bedrack was not true to size just to mention that


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Re: DB's Cage Canopy Build

Postby DeadlyBeast on Fri, 22 Jun 2018 1:57 +0000

Caleebra wrote:Which model did you download? The one i used in my build for the bedrack was not true to size just to mention that Sent from my iPhone using Tapatalk


No problem Arne - please find the below link

https://3dwarehouse.sketchup.com/model/a2fadca4b32219f5889a7c118c27bd0/toyota-hilux-2012-patrulla-equipada-subsemun

I got rid of the front and rear bar work, windshield wipers, roof top lights, added a hood scoop and changed colour.
This model may be slightly out of scale. I had to change the dimensions of the model using scaling tool to get the tub closer to 1600mm. It was about 50-100mm out or so in length if I remember correctly
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Re: DB's Cage Canopy Build

Postby DeadlyBeast on Sat, 23 Jun 2018 7:15 +0000

Considering Ally
50 x 5mm tube should be strong enough
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Just need to work out the rear quarters
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