Ramsey Worm Winch Modification
 

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.

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.

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

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

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.

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

Milling the dog clutch.

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.

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

Looking good!