How to make a winch from a starter with your own hands

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.

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.

Hydraulic drive

A hydraulic winch is considered a more complex mechanism, as it has some additional elements, namely: a hydraulic drive, an oil tank and an oil pump. The device itself is quite bulky, so it is more difficult to assemble than other types of devices.

But a hydraulic winch has two big advantages: it consumes less electricity, but at the same time has more power than other mechanisms. Typically, winches of this type are mounted on very cool SUVs, as well as on tractors and walk-behind tractors.

Another version of a winch from a starter for household needs

For production you will need:

• Used car starter with a working motor;
• Flywheel with gear;
• Steel wheel disc, or two brake discs - for making a drum;
• Powerful bearing with a podium (a used hub assembly is suitable);
• Corners, channels - for making a frame;
• The usual tools are a grinder, a welding machine, a drill.

The starter can be taken from a Zhiguli if you do not need to move trucks. The rest of the design elements are whatever you find. In this case, a flywheel from a Gazelle, a hub and CV joint from a VAZ 2108, and brake discs from the same were used.

We twist the disks together in the form of a drum for the cable,

the remaining structural elements recreate the front wheel axle assembly. The only difference is that the hub body will be welded to the winch frame, and the flywheel gear will be attached to the CV joint “grenade”.

The bed is made from a powerful channel and angles. There is no point in dwelling on this structural element, unless we pay attention to strength.

We weld the finished structure of the drum and support bearing to the frame. Please note that the entire power part is supported on one support. There is nothing wrong with this; the hub assembly can withstand such loads constantly.

We weld the outer “grenade” of the CV joint to the flywheel. The quality of welding must be high, since this unit will be heavily loaded. In this embodiment, gear architecture was used. The coupling is machined to accommodate the CV joint.

“Having measured seven times,” we weld the eye to secure the starter housing.

The design is ready, testing can begin. The solenoid relay bendix must be locked in the maximum engagement position. This can be done by welding. The relay itself performs the function of a starter.

A nice feature of this winch is the presence of reverse. By switching the polarity on the power supply, we can start the starter motor in the opposite direction. The design of the reverse trigger mechanism can be achieved using power relays.

Source

Stage-by-stage execution of work

Below are detailed instructions on how to make a winch with your own hands using a Zhiguli starter. The choice of this starter is due to the fact that it is as compact as possible and has a high degree of reliability. An additional advantage is the ability to purchase it for almost nothing on any spontaneous automobile market.

1. The power contacts of the retractor relay can be left if the load on the winch is significant. The bendix mechanism, in turn, must be removed along with the cone housing.
2. Since the mechanism in this case is low-power and compact, there is no need to create a gearbox from a flywheel gear. Just pick up a knot from a large drill. The gearbox must be a reduction gearbox.
3. Separate the Bendix housing from the winch and locally mate the gearbox shaft with the corresponding part of the starter motor. This can be done either by creating a transition coupling with cotter pins or by classical electric welding.
4. There is no need to install dampers as they will break anyway.
5. The use of a planetary gearbox will allow you to increase the gear ratio if necessary.
6. Use an appropriately sized pipe to cover the space between the motor and gearbox so that the operator is protected from rotating elements.
7. The motor housing and gearbox must be securely connected, but not with simple threaded rods.
8. Make a drum from a cut of sheet iron a couple of millimeters thick and a steel pipe with a diameter of 1.2 cm. Weld round jaws to the pipe and drill a coaxial hole for the power shaft in the center of each side part.
9. The power shaft must have a standard pair of working gears, otherwise it will be problematic to pair the main sprocket with the output of the gearbox.
10. Securely weld all the elements together on the channel frame. Backlashes are unacceptable.
11. Make the side walls from sheet iron up to 5 mm thick. Thickness less than 3 mm will not work.
12. Using powerful bearings with podiums, secure the drum. This stage is one of the most critical. Weld the podiums to the side walls.
13. The gearbox should be fixed on the frame so that its gear clings to the power gear on the drum shaft. Between the walls there should be a leash for the cable - an eyelet.
14. Connect the electric motor from the starter to the gearbox and give the winch a presentable appearance - clean the seams, remove rust and cover the surface with paint.

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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.

• 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.

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Rating of hand winches

Studying catalogs describing the best new products of the year helps you choose the right device for your car, garage or construction site. As an example, we suggest looking at a small TOP of drum and lever type devices in different price categories:

1. Matrix 52225 is a popular budget device with a tractive force of up to 1.6 tons, weight 6 kg, gear ratio 15:1, cable diameter 5 mm, cable length 2.8 m.

2. STAYER 4310-2 – load capacity of 1 t at a lifting height of up to 3 m, develops a force of 2 t on terrain with a slope of up to 15º, has a reinforced body.

3. Haul-Master 95541 – Works with polyester flex belt, steel body, 900 lb (approx. 400 kg) attachment capacity.

4. Sportsman W1000 - Comes with 32' heavy duty steel cable, 1000 lb (454 kg) maximum lifting capacity, 2.7 kg weight, forged gear, anti-corrosion body coating.

5. Invincible Marine BR59230 - Cable Hand Drum Winch, Corrosion Resistant Assembly, Galvanized Frame, Hand Winch Capacity 600 lbs (up to 270 kg), Compact size suitable for boat or garage.

Do-it-yourself winch from a starter: drawings, photos of production

Homemade winch from a starter: drawings of an electric winch, photo of making a homemade product with your own hands.

To make a homemade winch, the author used a starter from a VAZ 21015. The engine from a car starter is designed for short-term operation and quickly overheats, but is quite suitable for making an electric winch.

We will also need a reduction gearbox from a hammer drill; you can find a gearbox at a flea market; in this homemade product, the author took a gearbox from an old Soviet-made drill with a gear ratio of 1 x 20.

The motor shaft needs to be connected to the gearbox shaft; this can be done using an adapter coupling and cotter pins, or simply weld them together.

Assembled into a single body.

Now we will make a drum for the winch from a piece of metal tube and sheet metal 3 mm thick.

A bolt is fixed in the pipe for fastening the cable.

We cut out two circles from metal with a hole in the middle and weld them to the pipe.

The gear and shaft need to be welded to the drum. In this homemade product, the shaft and gear are taken from a decommissioned oil pipeline valve mechanism.

The drum rotates on two bearings that are welded to the winch frame covers.

Side covers.

Drum with gear assembly.

As an option, you can take the drawings of a hand winch drum.

To prevent the cable from flying off the drum, we weld a guide eye to the winch body.

Studs installed.

The gearbox is mounted on the winch frame; the author attached the gearbox using a pipe clamp for threading.

We compare the gear of the gearbox shaft with the gear of the drum. Gear ratio 1 x 5.

Reverse connection diagram on a winch.

We wind the cable onto a drum, the thickness of the cable is 6 - 10 mm.

Advice! Do not connect the electric winch to the car battery when the engine is off, the battery will discharge in a few minutes.

Also, you cannot cling to a metal cable the car from which the electric winch is powered; alternatively, you can use a fabric cable or remake the brush assembly on the electric motor, insulating the mass on the winch itself.

A homemade winch from the starter will easily pull a passenger car out of the mud, including a UAZ “loaf”.

Homemade author: Nikolay Evdokimov.

Interesting video: the author shows his homemade winch from a VAZ 21010 starter

Manual winch - design features, do-it-yourself manufacturing

Other power tools

06.12.2021

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8 min.

On the farm, it is often necessary to move a load over a certain distance or height. Car enthusiasts are faced with the need to pull out a stuck car or remove the engine when doing their own repairs.

In all cases, a manual winch helps out, the production of which can be done in-house. You should study the design features, use drawings and step-by-step instructions.

A selection of videos reveals certain nuances.

Devices are classified by design, method of actuation and other technical features. They are also divided into portable and stationary. Manufacturers often install permanent winches at the front of the car.

There are several designs by type:

1. 1. Manual, compact size. Usually they are drum-type, where a cable is wound on a reel, and the work is carried out by rotating the handle. The maximum cargo weight for such a device is 1 ton.
2. 2. Mechanical, which are driven by a motor. They do not provide for an independent moving unit. The structure is large and is used primarily in construction.
3. 3. Electric with drum. This option is preferred by drivers because a starter can be used for drive. It is capable of pulling out a stuck car weighing up to 4 tons.

Of particular note are the hydraulic devices. They have quiet operation and a large load capacity, but they are unreliable in operation.

The scope of use of devices for moving goods is the most extensive. If physical force is used, quite a lot of effort often has to be applied.

A homemade winch will help a person if he correctly assesses the severity of the work and the volume. The design necessarily includes a brake and ratchet.

Another option is a safe handle, which simultaneously serves to drive and fix the mechanism in a certain position.

Simple hand-held devices have a number of advantages:

• compact sizes, for which they are especially appreciated by car enthusiasts;
• instant readiness for use without special preparation;
• Possibility of use for moving cargo in horizontal and vertical directions;
• ease of maintenance - no complex and regular repairs are required.

The machine drive is used in simple cranes, scrapers, and drilling rigs. This is a winch with a different number of reels - from one to three. Driven by electric motors, diesel, gasoline.

Among hand winches, there are three types: lever, drum, mounting and traction. The first of them are the simplest: they consist of a cable, a ratchet or ratchet mechanism, and a lever. The advantage of the design is the ability to work without fixation on the base - simply suspended. The lever makes movements that activate the ratchet.

Lever design for 4 tons with locking in two positions

A cable is wound on the drum, which is fixed with cams without unwinding in the opposite direction. Its length is small - up to six meters, and this is a significant drawback. The advantage is the ability to develop a large traction force: 0.750–4000 tons, lift a load 4 meters.

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A drum or cable winch includes a support, a handle, and a gearbox. The basis of the design is the drum itself, a gear or worm gear. The first is preferable due to its ability to serve for a long time. For safety, a brake mechanism is provided to prevent the load from suddenly falling. To work, it requires fixation on a reliable base.

When the handle rotates, the force is transferred to a drum with a long cable - up to 40 meters. The developed traction force reaches 5 thousand kg. Various reel sizes allow the use of powerful cable up to 15 mm thick. With such a winch, it is easy to pull a car out of a ditch, lift reinforced concrete blocks, and plow summer cottages if the soil is not clayey.

An assembly traction winch is the same as a lever winch, only it does not have a drum. The body has clamps in the form of cams to create the required force. They are located in parallel, which allows you to evenly distribute the load on the cable and prolong its service.

A lever with a shear pin protects the device from overload and locks the cams if necessary. It is used for various purposes and is popular due to its technical excellence. Periodic lubrication is required for ideal operation of the units.

https://www.youtube.com/watch?v=2eGm6pMyIlc

Manufacturers often install winches on vehicles used for off-road driving. This unit helps you get out of a problem area or climb a slope. Domestic cars, such as Niva and UAZ, do not have such a device. After its installation, the SUV will be able to move through the most difficult terrain.

It is important to choose the right winch power. The indicator depends on the weight of the car, and additional equipment increases it. For various modifications of the Niva it is 1150–1400 kg, UAZ-469 and Hunter are heavier - 1770 kg. The force developed when pulling out the machine should be at least 2 times higher.

A hand-cranked device helps in most cases. But if road conditions are particularly difficult, a vehicle electric winch is required. Homemade is made using a vehicle starter.

Watch the video about the ratchet winch from KAMAZ.

There are situations on the road when you can’t count on outside help. The prudent driver has a crowbar in the trunk, which serves as an axis of rotation, and a piece of pipe as a drum. A lever is welded to it. The presence of a cable is assumed by itself. It takes a little sweat to get the car out of the mud.

Making a device that will help you out in a difficult situation is simple:

• The crowbar is driven into the ground and a pipe is put on. It should provide a place for attaching the cable - some kind of hole or welded ears.
• One end of the sling is hooked to the pipe, the other - to the car. Make a loop, insert a lever and begin to rotate.
• The cable is gradually wound up, the car moves slowly.

It is known that the longer the lever, the less physical effort is required. If the size is too large, it is inconvenient to use: the optimal parameters are 80 cm with a slight tolerance in one direction or the other.

The use of a manual mechanical winch to pull out a car requires compliance with certain conditions. Choose a direction that prevents the car from getting stuck even more in the mud. The wheels are set straight to reduce drag. If possible, choose a higher location for fixing the device - the required physical strength is reduced.

If you have a welding machine and an angle grinder, the device can be easily made quickly. Main components of the product:

• frame made of profile pipe 20×20 mm;
• drum made of 3 mm sheet metal, hubs made of the same material;
• shaft;
• 6 bushings 200 mm long from tubes with a diameter of 14 mm;
• lever, cable and carabiner.

This design can be easily converted into a winch driven by an electric motor or any other engine. You will have to find two sprockets with different numbers of teeth. The drive from the gearbox on the motorcycle and the driven one on the wheel will do. You will also need a chain of the appropriate pitch.

They start by making the frame, for which they cut rectangular pipes and form the ends at 45°. Lay out the parts on the table and grab them pointwise in the corners.

After checking the perpendicularity and dimensions, the seams are welded. If it is planned to install a motor, make a metal base with cut grooves and secure it.

Clean it with a grinder, sand it, cover it with a primer, then two layers of enamel.

For the drum, cut out 2 identical circles of 300 mm in diameter. Drill holes:

• for mounting hubs - 4 pieces;
• in the center - under the shaft;
• stepping back 70–80 mm - for bushings.

The hubs are fixed with bolts, the drum disks are connected with studs. Tube bushings are mounted on them between the circles. Secure with nuts and locknuts.

The structure is mounted on a shaft, which is threaded into the holes of the sheet metal cheeks. On one side from the outside there is a place for the drive handle, on the other, if provided, there is a large sprocket.

A chain is then put on it, which goes to the engine. To reduce the friction force, use bearings of a suitable diameter.

One end of the steel rope is fixed to the shaft and wound. A simple design has emerged that can move loads horizontally. If it is necessary to lift a weight, a manual hoist is additionally used or a cable is thrown over a block. The winch is also installed on vehicles.

Before starting assembly, mark the fastening points with your own hands, using not only the drawing, but also applying the existing blanks.

This will allow you to determine the correct location points where it is possible to cut something off or replace a part that is not suitable in size.

Quite stringent requirements are imposed on the operation of the mechanism: no wobbles, excessive tightness of fit, so that the parts do not wear out prematurely.

The proposed drawing is used as a guide for the work. The dimensions of the structure depend on the Glist gear. It is selected taking into account the required winch performance. Based on the parameters of the worm gear, a lifting device is manufactured according to the diagram.

Components and their role in the winch:

1. 1. The Glist gear, which must have strong teeth and sufficient thickness, transmits force to the shaft.
2. 2. It is made from thick-walled pipe. A round piece of metal with a diameter similar to the inner ring of the gear is welded at one end. To fix the cable, drill a hole through it.
3. 3. Bearings on which the shaft rotates. If the work is planned to be intermittent, it is permissible to use bushings.
4. 4. The case is durable and made exactly to size. The design must ensure that there are no gaps between the mechanism components.

Gear Glist

The frame is assembled from two pieces of channel with a wide flange of 200 mm, different in size: 300 and 400 mm. The long one is located on the right side, where the gear and drive handle are installed.

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