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2000bl winch hack tutorial
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miles&Jules
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Joined: 19 May 2010
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2000bl winch hack tutorial

Winch Tutorial
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Well we just hacked these new winches so ...of cause documented the process, so thought we would turn it into a tutorial...if this looks good enough ...then maybe someone can chuck this on the robo wiki?

So to disassemble the front of the winch.....remove the two bolts that hold the angle plate... this holds the cable reel to the gearbox .

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Then remove the 4 screws that hold the exceedingly lame aluminium face plate, to the gearbox and remove it (pic below) don't need it

then remove the second stage of gearing (pic below) don't need it

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Then you need either a 16mm bolt or you need to make a shaft that is going to hold the wheel to the gearbox.

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if you are using the trolly wheels like the $10 ones from super cheap...then the shaft/bolt needs to be 16mm thick.

Make sure either the bolt or the new shaft fit a bearing nicely and also fit into the hole on the top of the first stage of gearing...bolts usually have a lightly rounded top that actually centres in this hole nicely.

For this shaft we used a 17mm bearing so we lathed the shaft to fit that at the bottom.(you can just use the 16mm bearings that come inside the trolly wheel.

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now these are ready to be welded.

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So to weld these the easiest way to do it, is to put the shaft in the chuck in a drill press. We dremeled off the coating on these ready for the welds.

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The metal on these gears is only 3mm thick so be carefull not to weld to fiercely or you will seize them up.

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then cut a piece of 120 x110 x20mm thick hdpe or bread board or a 10mm plate of aluminium for the face plate.

We lathed a slot for the bearing...but you can use a hole saw to gouge out 10mm deep into the material so the bearing will fit nicely.

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now test fit

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now trim off the lame 1mm edge that surrounds the edge of the gearbox....then drill out the original face plate bolt holes on the gearbox...we predrilled pilot holes with a 3mm drill bit through out the back of the gearbox.
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then drilled em right out with a 6mmdrill

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then used this....homemade drill extension with the 6mm drill bit to drill through the gearbox holes into the faceplate(making sure the gear and shaft are all in position.)

then put 6mm bolts through and attach the faceplate(use nyloc nuts on the back)....you should be able to spin the shafts by hand....

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....then test it out with some tz85s Very Happy
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Post Sun Apr 21, 2013 1:12 am 
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RogueTwoRobots



Joined: 12 Jan 2008
Posts: 135
Location: Irvine, Scotland


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A nice step-by-step guide!

I'm currently embarking on a heavyweight robot project over here and doing some research into various drive motor options. Thinking that these might be one option (possibly with a transmission to the wheel to reduce shocks) but it's quite a compact robot as far as heavyweights go, so I'm just wondering if you can tell me what the length is from the front face of the HDPE/chopping board plate to the end of the motor can?

They should in theory have enough power to shift a HW since most winch motors seem to be around the 1hp mark (which is what most UK builders have in the form of the popular Bosch 750W motor) but just not sure as they're a bit of an unknown quantity in HW respects.
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Post Sun Apr 21, 2013 8:51 am 
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miles&Jules
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Cool glad ya liked it...be great to see em in a heavy weight.....its 175mm including the 20mm hdpe faceplate. Very Happy
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Post Sun Apr 21, 2013 10:06 am 
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marto
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Nice tutorial the only thing I would mention is a warning about the many types of motor which are available on ebay. If you get the wrong type it can be completely different so watch out.

Steve
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Post Tue Apr 23, 2013 3:00 pm 
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dyrodium
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Epic! I think this would work with the 3000lb winch that I got too, the output stage is the same. Smile Now lets all make lightweights using winch drive motors! Twisted Evil
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Post Tue Apr 23, 2013 3:04 pm 
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marto
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Nah Middleweights (non spinner) and setup the feather arena and sit inside that.
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Post Tue Apr 23, 2013 3:20 pm 
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Knightrous
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quote:
Originally posted by dyrodium:
Now lets all make lightweights using winch drive motors! Twisted Evil


Don't forgot to buy some BotBitz 85A's while your at it Razz
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Post Tue Apr 23, 2013 4:42 pm 
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dyrodium
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quote:
Originally posted by Knightrous:
quote:
Originally posted by dyrodium:
Now lets all make lightweights using winch drive motors! Twisted Evil


Don't forgot to buy some BotBitz 85A's while your at it Razz


Hahah was gonna grab 3 today cheers for reminding me. Razz Was just waiting for the stock to return to Aus XD

Also - wait till you see my pozible update video. Cool

edit: You got those fingertech switches in yet? Razz

edit edit: Hurr out of stock Laughing
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Post Tue Apr 23, 2013 4:44 pm 
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Tim



Joined: 30 Oct 2013
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Nice tut Man been hearing about these famous winches for a while now just came across it good work! Very Happy

Post Wed Oct 15, 2014 7:02 am 
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Valen
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the title you have says 2000bl (i'm guessing it should be lb? ;->)
Also linky for where to get the winches?
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Post Wed Oct 15, 2014 9:45 am 
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Knightrous
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quote:
Originally posted by Valen:
Also linky for where to get the winches?


www.ebay.com.au

I should do a tutorial for the 4000lb winches (1.3Kw) we used in Single/Double Dragon.
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Post Wed Oct 15, 2014 1:19 pm 
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marto
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Gotta make em work first.
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Post Wed Oct 15, 2014 2:01 pm 
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Valen
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~$70 the price one should be paying for them?
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Post Wed Oct 15, 2014 2:33 pm 
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marto
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About 90 now I think.

Steve
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Post Wed Oct 15, 2014 5:14 pm 
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Tim



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Wanda seems to go hard on them Very Happy

Post Thu Oct 16, 2014 12:45 am 
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