Warn 8274 DIY upgrades

[Mattrade]

I bought my fist lathe 2 months ago and have always wanted to build my own 8274 with free spool and twin motors. I have a 8274 I built with off the shelf upgrades works a treat but think I can build something similar for 1/10 th the price. So here we go.

[Mattrade]

Making a polyurethane gear support.

[Mattrade]

I turned down a Hilux free wheeling hub for the drum disconnect.

[Mattrade]

Tig welded drum gear to a fj40 short side axle shaft.

[Mattrade]

keeping the drum diameter stock to keep the winch speed high, but making it wide for rope capacity.

[Mattrade]

Drum calculator recons i can fit 107m of 10mm on but will never need that much. Heaps of room so i never need to worry about how its spooling.

[stealth]

Love it!

[Crash bandicoot]

Nice

[Mattrade]

Was planning on a air free spool but was thinking simpler the better so going for a stainless steel rope that u pull to engage free spool. works mint on the shop table

[mudlva]

um yeah but naaah... the hub will turn so it will eventually wind up the rope or similar to a point where it will pull it to free spool. even installing a swivel my guess once full of mud would bind and then start creating issues.

nice job on the rest tho

[Mattrade]

Next on the list is a new brake. I love how the red winch hornet 2 has the air brake and want to try do the same. This is a $40 brake for a pit bike off trademe.

[Mattrade]

Hey mudlva its a bolt through two holes so can spin i hope. Im building and working out as i go so Im sure it will need a lot of refinement.

[Mattrade]

Next is to make up a bracket to hold the brake caliper.

[mudlva]

Hey mudlva its a bolt through two holes so can spin i hope. Im building and working out as i go so Im sure it will need a lot of refinement.

Sweet the test is in the real world operation.
Wondering if you could mount it in some form of staple or bracket to stop it form turning. Just a thought...

[Mattrade]

Ya think u on to something thanks man i appreciate input, watch this space

[Mattrade]

5mm plate disc brake bracket.

[Mattrade]

Thinking of ideas to engage the brake. I want it to be held on by springs and lifted by something. This was my first idea its a solenoid from a starter motor, didn't work not strong enough, heated up quick and to short of a throw.
Next idea is a air ram, and its on its way from china

[sirLachlan]

I think the brake system is going to need a bit more thought on the whole .
What is the rpm increase /torque multiplication from the drum to the disk ? As a disk and pads isn't going to deal with the heat or a lot or torque at low rpm

Those disks are made from God knows what garbage. But it rusts unlike most oem bike brake disks . Also being Chinese you are limited on pad selection

I prolly would have gone with a twin leading shoe drum brake . As these are self boosting and require little effort to generate a lot of braking . Also it's the given brake design for stuff like ship whinchs and anchors etc . The large pad area will last a lot longer .
Aswell as needing no hydraulic system thus simplifying things greatly

But you've already built most of this so see how it goes . Put a lever back on the brake master cylinder and have as much leverage as your hand has for the air cylinder . So 100 Mm of travel on the air ram = 25 mm of travel at the master cylinder piston

Cool project other wise

[Mattrade]

Gearing is 1 turn of the drum is 6 turns of the disc. Making my brake 6x stronger. Had a small test last night with the motor on. I can stop it by pressing the brake cylinder down to the table. But it is a lot of gearing coming from the motor so is not straight away but think I can live with that. I hear u with using leverage to multiply the effectiveness of the air actuator.

The brake needs to be on the motor for it to be perfect... maybe next time ha ha

[sirLachlan]

Oh yea sounds promising .

[Mattrade]

[mudlva]

yep that works

[Mattrade]

[Mattrade]

Re design the free spool. The problem is that it has a spring to retract the locking teeth. U have to give the drum a back and fourth to get it to unlock. not really what u want when its mounted at the rear of your truck.

[Mattrade]

Also have a air ram to go on if i feel like being fancy

[mudlva]

Airs the ticket. It will hold it ready to pop to free. Quick tap reverse and it should pop straight out. It will hold the gear pressed ready to engaged and as soon as aligned it will pop back in. Will be way better than cable imho

[Mattrade]

Free spools done. Its working well. Still spring loaded for locking drum, and a pull for free spool. Used a bit of conveyor belt to stop the bolt from spinning.

[Mattrade]

Made a fixing point on the drum for the rope.

Reinforced the disc brake bracket.

[Clint]

Looking good! Another idea I've seen for actuating a freespool is to use hydraulics with clutch master/slave cylinders. Though as Mdlva says an air ram is good as once switched it will hold the pressure on until things line up & it can click in.

Cheers
Clint

[Mattrade]

My air ram arrived. It's a 50mm diameter with 30mm travel. It's got 10kgs of pull @ 90psi so should easily be able to pull my brake spring back.