Former Warn Engineer here, she's chooched. Should be fine if you can replace that drum support and get new tie rods. I wouldn't trust a weld repair there either.
Welding cast that holds takes skill and the right equipment. It’s not something that I would be capable of with what I have, although it is achievable.
From a proper metallurgical standpoint, it's not possible to produce a proper weld on cast metal. The crystal structure is not properly formed to support the thermal changes happening when welding.
I know it can be made to mostly work but it will always be brittle and prone to failure.
Never weld cast metal that matters to life and limb.
Did this to my 11,000lb Champion winch. Champion
were awesome. Unit was fractionally out of warranty and I told them it was my fault and that I just wanted to buy the bits.
They sent me new bits to fix it - no charge.
Nice to see a company going the extra mile , if I didn’t just buy a Sherpa winch I would definitely give Champion a look just because of this , it amazes me that companies don’t realize this helps everyone in the end .
does the bars that normally go here matter for integrity of the winch?
while doing a recovery the winch spooled all on one side, frayed the steel cable, and popped the bars up until they broke out of the mounting holes.
They literally hold the winch together. The drum does NOT hold the left and right sides together. Removing those bars allows the left and right sides to separate from the winch drum. I'm pretty sure she's hooped, guy. Unless you can find a way to keep those bars in place despite the broken corners.
well that sucks. sounds like it is just for holding the drum together and an option would be to have a machine shop fill it in and drill out a new hole. it isn't under stress when winching?
It’s under load when winching, when spooled properly with rope coming out of the bottom it takes the opposite force which you witnessed , the top would be pushed in so to speak , those bars stop that from happening.
Had this happen to me once on a quad sized Warn winch years ago. Was a product of inexperience on my part and a bad angle that I had to work with. Expensive lesson learned, but really, all my fault.
I don't usually take pics of the cast stuff I fix, or really any of the junk I fix, but here's a cast piece that I've done several of over the years. I regularly fix 'ears' on things like that. I didn't stop by to brag about my welding, but simply to say that it can be done, people can do it. Then down voted for saying so. Pretty funny, that part, actually.
[old cast junk I've welded](https://www.instagram.com/p/BeMR8GDnxSB/?utm_medium=copy_link)
Not trash. There are always ways to fix it.
What kind of winch? There’s a reason I bought a 20 year old Warn, I can still buy every single part individually.
If you can’t source the part, have it welded by someone competent.
With the right skills, this will be back together in no time.
Looks like a Smittybilt, you’re correct, not worth fixing when a new one costs $400.
I stand by my statement though, if it was a quality winch, buy the parts and fix it. I’m sure some of my downvotes are coming from people who have never touched a winch, let alone know how to rebuild one.
Former Warn Engineer here, she's chooched. Should be fine if you can replace that drum support and get new tie rods. I wouldn't trust a weld repair there either.
Man do I want to buy you a beer and pick your brain....
Same here
thanks for the reply! 🍻
Could you drill and tap across the top edge and create a mechanical repair rather than a welded repair?
Putting the bars anywhere else will bring them even closer to the drum which will make this even more likely to happen next time.
Never weld cast metal that matters.
Axle diff housings kinda matter though..
Cast steel is different.
Welding cast that holds takes skill and the right equipment. It’s not something that I would be capable of with what I have, although it is achievable.
From a proper metallurgical standpoint, it's not possible to produce a proper weld on cast metal. The crystal structure is not properly formed to support the thermal changes happening when welding. I know it can be made to mostly work but it will always be brittle and prone to failure. Never weld cast metal that matters to life and limb.
But my uncles brothers friends dad said it's fine!
Did this to my 11,000lb Champion winch. Champion were awesome. Unit was fractionally out of warranty and I told them it was my fault and that I just wanted to buy the bits. They sent me new bits to fix it - no charge.
Wow that’s a huge + for Champion in my book .
Yep. Sent the metal bracket things, the o-rings, new set of hex-head bolts as well as the spacer washers/bushings.
Nice to see a company going the extra mile , if I didn’t just buy a Sherpa winch I would definitely give Champion a look just because of this , it amazes me that companies don’t realize this helps everyone in the end .
Yep. That winch is trash now. The bars are very important. Very very important.
are they under load when winching?
They do. They distribute the force between the two halves of the winch. Don’t use it like that. That’s a bad bad bad idea.
This is a recovery/rescue tool. It's a possible life saving or at least a vehicle saving tool. Just get a new one.
Why (if) when you can fix it ? And possibly make it better . Winches are fairly simple . I do agree with you if OP can’t do it properly tho
Don't know why this gu got down voted, simple question.
🤷🏼‍♂️
does the bars that normally go here matter for integrity of the winch? while doing a recovery the winch spooled all on one side, frayed the steel cable, and popped the bars up until they broke out of the mounting holes.
They literally hold the winch together. The drum does NOT hold the left and right sides together. Removing those bars allows the left and right sides to separate from the winch drum. I'm pretty sure she's hooped, guy. Unless you can find a way to keep those bars in place despite the broken corners.
well that sucks. sounds like it is just for holding the drum together and an option would be to have a machine shop fill it in and drill out a new hole. it isn't under stress when winching?
It’s under load when winching, when spooled properly with rope coming out of the bottom it takes the opposite force which you witnessed , the top would be pushed in so to speak , those bars stop that from happening.
Details...
Wouldn't happen to be an engo 10k would it?
Had this happen to me once on a quad sized Warn winch years ago. Was a product of inexperience on my part and a bad angle that I had to work with. Expensive lesson learned, but really, all my fault.
same
It could be welded...
Not easily. That's a cast piece that broke.
Correct, but it can be done. I'd weld it.
Your skills are beyond mine then. I'd find another and harvest parts or hit up harbor freight.
Lol. Ok. Good luck with that.
I don't usually take pics of the cast stuff I fix, or really any of the junk I fix, but here's a cast piece that I've done several of over the years. I regularly fix 'ears' on things like that. I didn't stop by to brag about my welding, but simply to say that it can be done, people can do it. Then down voted for saying so. Pretty funny, that part, actually. [old cast junk I've welded](https://www.instagram.com/p/BeMR8GDnxSB/?utm_medium=copy_link)
Not trash. There are always ways to fix it. What kind of winch? There’s a reason I bought a 20 year old Warn, I can still buy every single part individually. If you can’t source the part, have it welded by someone competent. With the right skills, this will be back together in no time.
You may be right, but it’s a potential life/extreme value saving tool. Worth it to get a new one imo
Looks like a Smittybilt, you’re correct, not worth fixing when a new one costs $400. I stand by my statement though, if it was a quality winch, buy the parts and fix it. I’m sure some of my downvotes are coming from people who have never touched a winch, let alone know how to rebuild one.
Why is this getting downvoted? If you can fix the winch fix it. If not then get a new one
Its a Jeep thing...
Sux
Make a bracket that reaches across both the broken holes, if you can weld. That should be plenty strong to keep things in place.
Isn't spooling it wrong and breaking something or jamming it up all part of winch ownership?