Outer Limits 4x4 Board

I know there is another thread on dual motors this is a little more basic.

At the moment I am doing the standard rebuild on the 8274 hi mount winch I got over a year ago off ebay for $300. It worked fine when tested (I don't know why I pulled it apart come to think of it), but it is painted red and I am trying to clean everything up like the dood on pirate 4x4 did. But getting the red of in parts is prooving quite hard, might paint it yellow to match the car

My plans are to rewire the solenoids in a water tight box in the engine bay and have an in-cab switch - Fairly standard.

I want to know how guys go about waterproofing the motor & mainhousing. Is it just a simple matter of Silicon and more silicon.

Also the ellusive brake mod. I have yet to take the circlip of for fear of loosing all of those ball bearings. Has anyone on here performed the "Brake Mod" themselves, I think there is drilling and tapping involved basically gets rid of the circlip. Steps on how to do this please.. I will take it to someone with the necesary tools.

I have read that issue of 4wd monthly with Mal Leslie in it. So I sort of know what I want done.

Man these things are fairly straight forward. WHat has gone wrong with yours ? Is it primarily the motors that turn to shart ??

Thanks in advance,

Jeremy

Do you want to rebuild the motor for comp use, or just rebuild it for the odd weekend use. Either way, the only thing differnt you would do to a comp rebuild would probably be put a 24v or 6hp/7.8hp motor on it. I like the water proof box idea. I did it for all my wiring. Why dont you bead bast your winch to get all the paint off. Then weld 2 more supports out the back of the winch to keep the drum true, then you could put drain plugs in it for quick services. The list is endless.

Good luck with the brakeshaft mod, as the shaft is made of axle steel, wont be drilling that too easily.

I recently tried to get my brake off to look at it, but i couldn't budge it with tools at home, and from what i hear, they hardly ever pop off with the circlip off.

My brake circlip popped off under load and mangled the whole brake system on the winch.

Had mal do his work to modify it with the bolt n such and no further problems..

My advice would do the brake mod. I wasn't able to finish the Rotorua comp due to the brake coming apart twice! Also I'm using a 7.8 hp motor (superduty) and to water proof it I've sealed the ends. It runs a lot cooler than the standard Warn motor so I have seen the need for any cooling. After the last few hard runs with it, I've pulled the motor apart and it is perfectly clean inside so I'm quite happy with it. As my winch is quite old I'm replacing the shaft, main gear and bearing then getting th end drilled and tapped to replace the circlip. The worst thing about the circlip coming off is one minute you are going foward then suddenly you are fly backwards out of control. Not pleasant during a steep climb, I can assure you!

The brake mod dosen't do away with the circlip!! when i've gone them i've had the shaft un-hardened then i drilled and tapped it and then had it re-hardened, then made up a billet washer that's ressesed in the brake's side
to go over the circlip and stop it form being able to expand and pop off


also you can pump compressed air into the winch motor to allow the brush packs to run cool and not burn out

I am initially rebuilding it just for occasional use but...in saying that when this motor carks a much larger one will be purchased.

I thought that was what the brake mod did. Got rid of the circlip to prevent tonka's drama...

Evidently I haven't even tried to get the brake assembly apart. Might mosy on down to binskins and see if they can perform the necessary tasks. But looking at the winches on both the glenn's rigs (Binskins and Marshman - new owner) neither of them had the brake mod. It must get overlooked by a few..

I like the compressed air idea..

Also as far as waterproofing the housing when putting it back together. Silicon ?? Gasket Goo ?? The Same for the housing around the motor.

Thanks

Mudzuki wrote:Good luck with the brakeshaft mod, as the shaft is made of axle steel, wont be drilling that too easily.

I just did this mod. The shaft drilled and tapped with no problem. I used a cobalt bit, just to be careful, but it went smotthly. The normal tap went in easily. The shaft is rock hard on the outside. It might just be surface hardened.

I made up a little page showing the assembly.

http://members.shaw.ca/red90/8274_brake/8274_brake.html