A quick look at the Hickey worm gear winch

[jeffahart]

Originally Posted by dazza

Excellent, nice to hear.

I've been looking for a good solenoid location under my hood and keep thinking of your compact setup...

I'm on the fence if I'm going to mount the compact to the end of the case. I have to pull wire for the remote plug anyhow, it can't stay underneath; That would be ridiculous to try to reach under there to hook up the remote. So I'm thinking under hood for the solenoid, and I'm the sure about the remote plug.

Where did you mount your remote plug?

[jeffahart]

Originally Posted by dazza

Excellent, nice to hear.

You received that motor quick! I'll have to make a note in regards to Western Motor, I had never heard of them until now.

Oh, also... I did get it quick. I ordered from DB electrical and they have a warehouse in California. I site Western Motors because they are the Big Dog. I called them. They have the 10 spline, they have everything. But DB was a bit cheaper for the smooth shaft motor and easier for me the consumer. Western is a supplier. I also called DB to verify the model, then pulled the trigger on Amazon. Too easy!

[dazza]

I'm not using a remote plug, mine's bluetooth! haha, I wish, maybe I'd better get an app going for that! I was looking to maybe mount it next to the winch were there is extra space then realized (and maybe it's part of why you are not going with the compact) how low it would be, and could get very wet, very quickly.
Messing with the sidewinder so much recently, I assumed my remote plug was built in to the box as the sidewinder's is, but I had a look and forgot that is not the case. The older, much thinner plastic solenoid box doesn't have one. I may just use one of the sidewinder boxes as they are the same dimensions. I may fab one up myself. If you need dimensions let me know.

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[jeffahart]

Today I started cleaning things up and some other perfunctory chores. But while I was at it I decided to add zerk fittings to both ends of the shifting shaft on the clutch housing. Why? There are no plugs or seals on the shaft ends. And no bushings. So grease is really the only thing to seal out water and such. And with no grease fitting no grease!

I had purchased a gasket and seal kit from Pierce. It was $25 and I need seal any way so why not get the gaskets. Well, the transfer gasket holes did not line up on my case. Not sure if the pierce transfer is different or it is just poorly stamped. At any rate I had to pound out a gasket. I use the side of a ball-peen and razor. Also, a good tip my dad and I use to clean up the holes in your gasket is to keep different size expended casings from your firearms. .22, 30-30 ect. You can pound a clean hole using the brass shells. I always hated a messy edge from just shoving the bolt through the gasket paper.

Added grease fittings.


Pierce transfer gasket holes do not line up, so don't count on that one.


Pounding out transfer gasket.

[dazza]

Originally Posted by jeffahart

Also, a good tip my dad and I use to clean up the holes in your gasket is to keep different size expended casings from your firearms. .22, 30-30 ect. You can pound a clean hole using the brass shells. I always hated a messy edge from just shoving the bolt through the gasket paper.

Very nice, I keep thinking I want to order some leather punches but I don't need to do it very often so I haven't pursued it. The casings are perfect.

How far does your clutch handle move to engage or disengage? I thought it was supposed to go a full 90º but mine only seems to go about 30.

[jeffahart]

I finished assembly. It went pretty smooth except that the case is aluminum and bolt holes are stressed from years of stress or whatever. I chased all the holes. I came out unscathed except for one bolt hole. One mounting hole on back side of the spur case could not handle the big 34 ft lbs and supn. Oh well, I'll hit it with some JB weld later on an drill and tap it again, no biggie. Also, the Pierce seal and gasket kit for $25 was a bust. I had to make all big gaskets myself because theirs did not match up, so all I got out of the kit was two seals and three small gaskets, rip off!

Also, I took some time to take the brushes out of the old 10 spline motor and reassembled it... and it works now. Great, it's no good to me now. But, I'm kinda glad it went on the blink because now I know how costly they are to replace.

Filled case and transfer capacities and let it set a few hours with no leaks, bench tested and installed. Now I need to get a fairlead and cut a hole in the bumper.

Filled capacities and no leaks


Bench testing


Installed

[jeffahart]

So the winch is officially ready for recovery action.

Today I wired up the winch and wound up line.

I put the solenoid on the driver side right above the horn. Not sure if I'm going to get another battery. I like this location.

Now I need to cut four holes in my bumper for the clevis mounts, fairlead and a hole for the remote plug.

solenoid


Wired motor


Remote plug wire lengthened to reach through bumper


Clevis mounts mocked up


Ready for action

[dieseldude4bt]

I always liked the power wagon ones.
I have one that i keep thinking I might put on my truck instead of the Koenig that is on there now, it has been on there 26 years with only one failure osan upgrade isn't really needed but it would be cool

[dazza]

Jeff, here's a shot of the skid plate/winch from see-ten's post about an article regarding Hickey's C10. I just need to find a pic as to how it's (skid plate) mounted in the rear.

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[dazza]

One thing I noticed about the article though, the truck shown racing doesn't have the same bumper as the picture I copied and posted. It's hard to see but I don't really see the winch either.

[jeffahart]

Originally Posted by dazza

One thing I noticed about the article though, the truck shown racing doesn't have the same bumper as the picture I copied and posted. It's hard to see but I don't really see the winch either.

Thanks for posting the link, nice article.
Ya, the photo of the truck with the winch is a K and not the race prepped C.

The information on the skid plates from this era is somewhere between sketchy and non-existent. Back then everyone made their own bumpers for winches. That's probably why we're not finding many examples.

I guess we just need to build some drop blocks(or whatever makes sense) off the cross member so the back of it doesn't flipper flap.

I'm going to build the skid plate when I have some time. But, I doubt I will keep it on. I just want to complete the setup, I've gone this far. But for running the winch, I really like to have access to the drum. Once you put the skid plate on you can't even see how your spooling. Plus I like seeing the winch in general. It's my Picasso at this point, and I want to see it!

[dazza]

I'll let you know when I get the skid plate on, somewhere here, in this garage is the answer... it will reveal itself I'm sure because it wasn't flipper flapping when I started this project!

[jeffahart]

Originally Posted by dazza

I'll let you know when I get the skid plate on, somewhere here, in this garage is the answer... it will reveal itself I'm sure because it wasn't flipper flapping when I started this project!

Cool, you'll probably find some brackets somewhere you forgot about!

I got my fairlead it the mail this week. I'm going to hack some holes in my bumper this weekend and get the bumper back on.

[jeffahart]

I cut slots in the bumper Saturday for the fairlead, clevis mounts, and remote plug.

I used the extra Long D-ring/Clevis Mounts from Chassis Unlimited. They mount with 3/4" high strength bolts. I also used a cheap steel Smitty Built fairlead off amazon, mounted with 1/2" stainless bolts.

Tip on cutting the bumper. If your bumper is chrome don't try to scribe or pencil in lines. The lines get lost in the mirrored reflections on the chrome. So, if your cutting close to the lines your eyes can pickup a lot of static. Tape out the square. The bumper is pretty thin, as far as metal goes, so you can cut it nicely with a jigsaw. Just drill a couple starter holes, jigsaw as close as you can. Dremel to fine tune then clean up the corners with a hand file.


Here's the completed bumper.

Now I need to make an extended clutch lever to come up through the top of the bumper. Otherwise I'll always have to reach way underneath to switch the lever to engage or free spool.

Holes cut out.


Competed bumper install with winch.


extended clevis mount

[BLT gmc]

Jeff, this looks great. I'm very impressed. Bruce
Posted via Mobile Device

[jeffahart]

Originally Posted by BLT gmc

Jeff, this looks great. I'm very impressed. Bruce
Posted via Mobile Device

Thanks Bruce!
It's been a fun project. Now I just need a lever extension and skid plate and it will be a wrap!

I will post pics of the lever extension that came with the winch. Now that the winch is actually installed you can see how the last owner had it setup!

I plan to make one that comes out in front of the grill.

[dazza]

nice job! a jigsaw? really? I had visions of a torch. Good to know.

[jeffahart]

Original winch owner used this piping with a small offset and a set screw. It was accessed by popping the hood and reaching between the grill and radiator. He my not have had air because it comes pretty close to my condenser. But I would rather not pop the hood to operate the winch anyhow.

This morning I did a mock up of a flat bar extension to come up through the bumper right in front of the grill. It has a lot of holes for mock up. It bolts to the clutch handle and snakes through the bumper in front of the grill. I had to jockey it around a bit to get it were I wanted, so I bolted the joint at first to get the angle correct and height on mounting on clutch handle, then I welded the joint. Guess I never took pics of it coming through the bumper in front of the grill. Now that I have it mocked up I can cut, bend and weld a clean one. Then I'll post some installed pics.

Original owners clutch handle extension


Clutch handle extension coming between grill and condenser.


My flat bar extension side view. More offset to come out through bumper.


Front view of flat bar extension.

[jeffahart]

Finished making a hasp plate for the extended handle a few days ago, finally installed it today.

About the extended handle and hasp plate. I decided that I did not like the idea of someone being able to walk by and maybe slap the clutch lever and set the spool into free. Although I keep a bit of tension on my cable, and it is hard to move the handle, I am a bit cautious. With a short 6" handle you probably need to pull pretty hard to get it into free with out letting up tension on the line. But now my handle is probably close to a foot or maybe 10 inches longer, much more leverage. So I drilled a hole in the handle where it protrudes from the bumper; and made a hasp plate with a corresponding hole. Put on a 5/6" hitch pin to keep it locked down.

The extended handle works great! Here's the results.

Hasp plate masked for lettering and final black coat.


Hitch Pin


Installed with hitch pin. There is 1/4" between the handle and the hasp, they never touch. The handle does not rattle around at all.


The setup works great.

[dazza]

Nice one, you think maybe a lock would be better so nobody will play with it?
From free to lock, approx. how many degrees? 12 or so?

[jeffahart]

Originally Posted by dazza

Nice one, you think maybe a lock would be better so nobody will play with it?
From free to lock, approx. how many degrees? 12 or so?

I would guess less than 10 maybe 8. You don't have to move it very far to slap the dog to clutch. But if you're needing to know I can put an angle finder on it for you and let you know the exact movement.

Thought about a small lock, but if someone really wants to take the time to remove the hitch pin and mess with it.... then I probably got bigger problems. Plus I lose keys; and I like the convenience of everything accessible up front and ready for service, kind of a no frills deal.... just business.

[jeffahart]

Calling this project done for now. It'll be awhile before I get around to making a skid plate or custom bumper. Though I have decided on an aux battery setup in the near future. I didn't mind cutting my bumper, taking a serious look at it I decided I need an new one.

Before and after pics.

[BLT gmc]

Nicely done, really looks great. How do you post pics here? I use your thread as inspiration to start my worm drive rebuild. Bruce
Posted via Mobile Device

[jeffahart]

Thanks Bruce, I really love the winch!

Posting pics is a two part deal.
1) Go to manage attachments below your post, before you submit the post,and browse for the image and click upload.
2) After the image is uploaded go to the paper clip in the tool bar and select the image to get the tag of the image to show in the text you are typing. This way you can write something above or below the image, by typing above or below the image tag.

If you only do step 1 your pics will be lumped together.

[wazzabie]

nice write up. i have a worm drive winch. the clutch handle is stuck and i can't move it to free. what do you think is wrong?