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threepiece 02-12-2020 11:53 AM

Ramsey Worm Winch Modification
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This winch is part of a different thread called “Quick Attach Dump Box” in the Fabrication forum. I thought it interesting enough to hold its own here.

The objective here is to make a narrower spool and install it in my existing Ramsey RE8000 winch. The result will be much like the one shown below. The winch is to be used to tip a dump trailer. A narrow spool will package better on the 3” mast that it will be mounted on.

threepiece 02-12-2020 12:08 PM

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Here I am turning one of the spool flanges. The part is being held to the jaws of the chuck by the axial force from the tailstock live center.

threepiece 02-12-2020 12:21 PM

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The chamfered ends of the hub and a gap created with welding rod both help to improve weld penetration and create a weld fillet.

threepiece 02-12-2020 12:26 PM

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To protect the rope, the weld is now being cut down to a somewhat smooth radius.

threepiece 02-12-2020 12:32 PM

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After cutting with a HSS tool.

Operations like this invite chatter. I mitigate the chatter by moving the tool from one side to the other in a series of little cuts.

threepiece 02-12-2020 12:37 PM

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Boring the center and cutting the dog clutch feature of the drive flange. Notice the opposite flange is not on yet.

threepiece 02-12-2020 12:40 PM

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Milling the dog clutch.

threepiece 02-12-2020 12:46 PM

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I saw an opportunity to provide a bit more integrity here by adding two plug welds even though I doubt that it was needed. The load path goes through this flange into the hub and then to the rope.

threepiece 02-12-2020 12:54 PM

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The rope attaching feature has been added to the hub and now the opposite fillet weld is to be cut.

milomilo 02-13-2020 01:10 PM

Looking good!

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