A winch is a necessary element of vehicle equipment if you plan to travel off-road. It can also come in handy in urban conditions if a wheel gets stuck, but in difficult terrain, where there is no way to call for help and the car is stuck on the very bridge, the winch is indispensable.
Often SUVs are equipped with this device at the assembly stage or you can buy it. But a homemade winch for a car, if you look at it as an ordinary task, is completely within the capabilities of anyone and does not require an engineering education.
In addition, such a device can replace a construction crane if everything is calculated in detail, a drawing and a work diagram are made. This will be more effective than using a hoist. Such a mechanism can be installed on a trailer or MZSA trailer.
What types of winches are there?
Conventionally, they are classified according to:
It is not at all necessary to purchase a device. Making a manual winch with your own hands is quite simple. First of all, you need to decide on the type and parameters of the device.
The device is equipped with a so-called “anchor”, which clings to a hard surface and helps to pull out the vehicle. A do-it-yourself anchor winch can be made from almost any scrap metal. It doesn’t matter what the “anchor” looks like, the main thing is that it clings well and does not deform under high loads.
While using the device, it is prohibited to stand within the radius of the cable.
Design and structure
If you need to make a winch for a car or an ATV, especially if you are regularly involved in extreme sports, then first of all decide on the weight that the winch will need to lift. For example, the average weight of an ATV is only 400 kg, so a winch with a traction force of up to 700 kg or 1 ton is sufficient for it. If we are talking about a car, then a more powerful unit with a lifting capacity of at least 3 tons is required.
Important! You should buy or make a winch yourself with a reserve, otherwise you can find yourself in a hopeless situation in a difficult situation. So, its power will depend on the applied load on the winch, and accordingly, the dimensions of the mechanism, whether it is electric or a hydraulic winch, does not matter
The more powerful it is, the larger its size will be, which is quite understandable. The first step is to understand the design. Although, in essence, they will differ only in the drive device, otherwise they are similar. The design of any winch includes the following functional units:
So, its power will depend on the applied load on the winch, and accordingly, the dimensions of the mechanism, whether it is electric or a hydraulic winch, does not matter. The more powerful it is, the larger its size will be, which is quite understandable. The first step is to understand the design. Although, in essence, they will differ only in the drive device, otherwise they are similar. The design of any winch includes the following functional units:
- Drive motor. An organ that creates the initial torque transmitted through the gearbox to the drum.
- The gearbox is planetary or simple stepped or worm. The design depends largely on the weight of the load, but generally a planetary reduction mechanism is used.
- The shaft on which the drum is located. A cable is wound around it during the process of lifting a load or dragging it. In simple automobile winches, designed for light weight, there is only one; in powerful ones with a traction force of more than 10 tons, there can be 2 or more, which is explained by the theory of blocks.
- Cable with hook. One of the main components due to which the load is dragged. Usually it is made of steel from individual cores.
Do-it-yourself winch from the starter
A homemade winch from a starter is made from materials that are always available in the garage. The basis, of course, is the starter, and the device itself runs on battery power.
It is desirable that the gearbox for the winch be planetary. You can find it on old Zhiguli models.
For manufacturing you will need: cables, cable, gears, drum, starter, gearbox, sheet of metal.
With this set of parts you will get a 12 volt car winch with your own hands. It should be taken into account that such a motor will consume a lot of energy from the car’s on-board network, so it is convenient to use it only when the motor is running.
A 220V electric winch with your own hands is suitable for household use. It is irrational to use a powerful engine here; a self-generator is quite suitable, which is connected in such a way that it works like an engine.
If you use a starter, the device will be more compact. Of course, it is not designed for a powerful load, so it will not work for a long time. Converting a starter into an electric motor with your own hands is quite possible, but this process is quite technically complex.
A do-it-yourself winch is made as follows:
Source
Features of application
The winch is a highly specialized, but at the same time universal type of traction mechanism, which has become widespread not only for use as a winch. They are used in the following areas:
- During construction, for lifting heavy loads to heights. Both mechanical and electrical devices are used.
- To evacuate cars stuck in a quagmire, then a winch is installed on the car itself.
- In agriculture, for dragging and lifting logs and other heavy objects to a height.
Disassembling the Chinese ratchet
To begin with, the cheapest ratchet for a Chinese truck was ordered. After receiving and inspecting this spare part, I began to think about further actions.
First, I cut off the rivets and removed the covers. I also unscrewed the plug and pulled out a spring and a ball - this was a worm stopper, it will no longer be needed.
Making a winch
It was decided to make two drums for uniform winding of the cable. To make the drum cheeks, collapsible VAZ generator pulleys were purchased.
Although you can make such washers yourself, I liked this option better. No bearings were needed.
A 10 m long cable was also purchased.
I couldn’t find a shaft with the corresponding splines, and I didn’t really look for it, so I just decided to make a shaft from a tube and weld it into the gear.
Purpose of the device
When driving off-road, a driver may encounter an insurmountable obstacle. Then the car will have to be pulled out of the mud or sand with something. A winch is the ideal tool for this. Some vehicles have the device installed on the front bumper from the factory. Purchasing a ready-made winch can cost a lot of money, so it makes sense to make it yourself using improvised materials.
A factory or homemade winch with a manual drive (or with an electric drive from a starter) allows you to pull out a car without a tow. Experienced car enthusiasts prefer home-made devices that fully meet their needs. Factory winches often fail or cost a lot of money.
There are different types of structures. It is impossible to say unequivocally which one is better. Different types are used for different situations and purposes.
additional information
It is impossible not to separately touch upon several issues of using a winch. Firstly, it can be permanently attached to the car, most often at the front. However, in this case, its mechanism is exposed to dust, dirt, and moisture, which is not good for it. To avoid this, many drivers practice using a portable winch, which is usually stored in the trunk of the car and removed if necessary. Such a winch can be installed not only in front, but also in the rear of the car, such as in the photo below.
To do this, as a rule, you only need to install an additional platform on the bumper (front or rear), to which the winch is attached.
A few words must be said about how to connect to the battery. An electric winch is a powerful consumer of energy, and therefore, if it is frequently used off-road, it may very well become possible for the original “battery” to be completely discharged. To avoid this, in some cases it is worth considering an independent battery to power such a device.
Device types
Classification is the first thing you need to know about the traction device. They are divided depending on the type of design, drive and technical features. Some types of winches are easy to make yourself - this is the simplest mechanism with a manual drive .
And complex structures will work reliably only if they are manufactured in a factory. This specificity must be taken into account when choosing a type for self-production. There are removable and stationary winches. The first option can be removed from the car, carried out maintenance or used for other economic purposes.
Classification depending on the type of drive:
- Manual. Its advantages are its small size and relatively light weight. The work is carried out according to the drum principle. The cable is pulled onto a separate reel, and it is rotated by hand. The disadvantage lies in the limitation of the mass with which work can be done - no more than 1 ton.
- Mechanical. The drum with the cable is rotated by the machine's engine. The design is heavy, so car enthusiasts rarely use it.
- Electric. The best option is for the drum to be driven by an electric motor. The latter is powered by a battery or the vehicle's electrical system. The load capacity in this version is 4 tons.
- Hydraulic. The design is complex, but it works silently and with great traction force. But such systems are unreliable and expensive. Another drawback is that it is impossible to make a hydraulic drive system yourself.
The manual winch is ideal for DIY. The system has a simple design that can be easily made from available materials. There are no complicated moving parts. You just need to decide on the parameters. If desired, you can install an electric motor on such a device, which will eliminate physical labor.
Conclusion
In some cases, a self-retractor is quite capable of replacing a winch. Of course, if the car participates in competitions or is used on very difficult off-road conditions, where it needs to be pulled out of captivity every few minutes, then it is better to use a winch, and of considerable power. If the car is used for fishing, hunting or other rides on not very difficult off-road conditions, then a self-extractor is quite suitable. Of course, a winch is in most cases more convenient and preferable, but given its cost, it is not always available. A self-puller will cost a ridiculous amount, but it is quite capable of coping with tasks that are usually assigned to a winch.
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A simple option made from scrap materials
Some motorists often drive into a field or forest, which may result in problems negotiating difficult areas - mud and sand. The car gets stuck, and you have to puzzle over how to get it out. The simplest hand-made homemade winch can be made in the field.
- Scrap and pipe cuttings.
- Cable.
- A piece of pipe for a lever.
It is unlikely that you will have the materials with you on the road. But everything you need can be found in the nearest village. Instead of a cable, a strong rope will do.
Manufacturing procedure:
- Drive a crowbar or a small diameter tube into the ground to create an axle.
- A larger diameter tube is placed on the axle, to which a cable is attached.
- A lever is slipped under the lower turn of the cable. This could be another tube, a shovel handle, or a pole. The main thing is that the material is durable.
With such a device, which can be assembled in ten minutes, you can move any heavy object, not just a car. The lever is rotated so that the cable is wound around the pipe. Such a manual winch will help to quickly solve the problems of moving heavy loads. This is not a full-fledged device, but it will get the job done.
Gearbox selection
The next problem is the choice of gearbox. Any 220 V electric winch with your own hands must contain a mechanism that will transmit rotation with a large traction force. There are the following types of gearboxes:
- Worm drives transmit rotation at an angle of 90 degrees and do not require braking devices, as they have good self-braking properties.
- They are not used for winches due to the complexity of the perpendicular arrangement of the main drive and secondary shafts.
- Cylindrical, are one or more pairs of gears in one plane, meshed. Rotation is transferred from the smaller wheel to the larger one. They have high reliability, but less tractive effort. Convenient for use when constructing homemade winches.
Planetary gearbox, the most common at the moment. It usually consists of 3 satellites, a sun gear, a ring gear and a carrier. They have an increased working life and transmitted power, but are complex in design.
The simplest solution when manufacturing a unit, an electric winch for 220 V, of course, you can always use a converter, especially since ready-made high-power devices are available for sale. An asynchronous motor can be used as a drive motor, but it is better to use a motor from a washing machine. Modern models are quite powerful and productive.
Manufacturing a system with a universal drive
The manual system is easy to manufacture. Of the special skills the master is required to do, only own a welding machine. Any metal will do the job. The appearance of the device is not so important, the main thing is performance and resistance to heavy loads. The frame should not be deformed.
Materials and tools:
- Rectangular tube for frame.
- Shaft for the drum, you can use a round tube.
- A sheet of metal with a thickness of at least 3 mm for the manufacture of drum disks.
- Threaded rods M10-M12, 24 cm long – 6 pieces, nuts.
- Tube diameter 14 mm - 6 identical pieces of 20 cm.
- Asterisks - large and small. Chain.
- Hubs to secure the drum to the shaft and secure the shaft to the frame.
- Drive lever.
- Cable with carabiner.
- Welding and electrodes.
- Grinder and grinding disc for it.
- Paint and primer.
- Wrenches included in the set.
Some materials are better purchased - for example, tubes for the studs and shaft. The rest can be picked up from old mechanisms - cars or motorcycles. Any metal will do, even used.
Manufacturing procedure:
Assembly Tips
Design development is carried out carefully, as well as assembly. The task is to treat each operation as responsibly as possible. The goal is to complete the assembly with high quality. This will avoid troubles when operating in extreme conditions. Therefore, there is no need to force the work, even if it is really necessary.
Steps to achieve high build quality:
- The work is done slowly and thoughtfully. A raw, unfinished unit cannot be used.
- Follow the drawing.
- Weld seams are treated with an anti-corrosion compound. Welding is done in carbon dioxide to obtain a high-quality seam.
- The electric drive control panel is placed as far away from rotating parts as possible.
- Electrical wiring is carefully insulated. The contacts are protected by additional insulation from moisture and dirt.
Negative results often arise due to hasty actions. The issue of moving cargo in a horizontal plane with its own device will be successfully resolved. To lift loads above the ground, the cable must be pulled over a strong support.
One of the popular ways to make a homemade electric winch is to use a car starter. This device is equipped with a powerful high-torque electric motor with a supply voltage of 12 volts, which allows the winch to be used on an SUV.
When manufacturing, you should remember the limitations:
- The starter is designed for short-term operation. This does not mean that it will immediately burn out under prolonged load, but the motor housing does not provide sufficient winding cooling. If you plan to use the winch regularly and the work periods will be long, you should take care of additional cooling. For example, weld aluminum corners onto the body as cooling fins;
- The car starter is started using a retractor relay with a bendix. You don't need a solenoid for the winch, but a contact starter wouldn't hurt. The current at the contacts will be large, and it is better to leave the standard switching circuit. Depending on the gearbox used, the bendix should be fixed by welding in the position of maximum engagement or removed from the solenoid relay;
UAZ 3962 My model is on the list › Logbook › Wheeled “winch” aka “self-puller”
When I bought the jack, it turned out that it would not be possible to use it on a loaf, and then the idea came to me to make such a gadget that would allow me to jack the wheels.
Thought and done! It took two old brake drums and ten homemade stud nuts from 45X. Here is the result: But in the end it turned out that the idea of guano would not work in real conditions anyway. And it turned out that it all really works, like a self-puller... The first pancake was lumpy - there was no anchor (it’s done now)
the second application and subsequent ones are successful
With a free differential only on both bast shoes and a block is required
Well, a little video from before the anchor era:
I unsuccessfully tore the turf there and sat down on level ground, almost on the bridges
Or you can use it as a stationary swan or a second pair of wheels:
Impressions of the device: advantages 1. cheap 2. compact 3. really works, but I don’t recommend installing it on the front axle. disadvantages: 1. takes a long time to bring into working position 2. to pull forward, modification of the front bumper is necessary. 3. in a hard rut you can hang on them Summary: The device is useful and is permanently registered in the car. Here's how I broke this device (the bugs have now been fixed) And this version No. 2, by the way, is also not successful...
How to make a winch from a starter
Let's take the Zhiguli starter as the initial donor. It is quite reliable and at the same time has a compact size. Another advantage of this choice is that a VAZ starter can be found almost for free at any dismantling of domestic cars.
The drawing shows the device and components of the starter. In the upper part there is a retractor relay with power contacts. They can be used if large loads on the winch are expected. On the left is the bendix mechanism, which must be removed along with the cone housing.
Since we are talking about a compact, low-power mechanism, it makes no sense to make a gearbox for a winch from a flywheel gear. It is enough to pick up a unit from a large drill. Finding one will also not be difficult, since there are more tools with a burnt out motor at flea markets than with a broken gearbox.
There are no special requirements for the gearbox, the main thing is that the diameters are more or less suitable.
For our adaptation, of course, we need to reduce the speed.
We separate the Bendix housing from the winch, and we are left with only an electric motor with a rotor shaft. The coupling of the gearbox shaft with the mating part of the starter motor is done locally. There are many ways - from banal electric welding to making a transition coupling with cotter pins.
The principle of operation of pulley hoists
The only simpler device for moving heavy objects is a metal scrap. The main element is a wheel with a chamfer in the middle of the outer surface, the axis of which is fixed to the ceiling beam. You can throw a hoist over it, and the lift with a gear ratio of 1 to 1 is ready. To increase the leverage, let's pass the hoist through another loose wheel, the axis of which is connected to the load, and fix the hoist at the top of the structure.
The gear ratio will become equal to 2. Now we will attach another wheel to the ceiling, and pass the end of the hoist through it, securing it to the axis of the lower wheel. The gear ratio will become equal to 3. And so on, by adding one wheel at a time and changing the mounting location of the hoist, you can increase the gear ratio.
The location of the wheels relative to each other may be different.
The most compact designs are those with single-axle wheels. The design of such devices has two wheel holders. Having studied the drawings of the chain hoist, it will not be difficult to assemble it with your own hands. You will need two clips:
- traverse;
- carrying bracket;
- cheek for mounting parts;
- wheel (block);
- emphasis;
- bearing;
- sleeve;
- axis;
- axle holder;
- bearing oiler;
- hoist limiter;
- screw;
- bearing;
- cheek.
The end of the hoist is fixed to one of the clips.
Pulley hoists also have disadvantages. To increase the gear ratio by 1, you need to add one wheel each time, as a result the weight of the mechanism increases. In addition, bending the cable on each wheel requires force, reducing the efficiency of the device. You can reduce these losses by increasing the diameter of the wheels, but at the same time there will be an increase in the weight and dimensions of the pulley. Other types of lifts do not have these disadvantages.
