Member Since: 29 Oct 2011
Location: Staffordshire
Posts: 502
New winch on D4
This is my very slow paced winch install. I thought I would share it as I go. Dont hold your breath though.
Installation is a Superwinch Tiger Shark onto an Uncle Rays hidden winch mount.
The winch mount is really well made and comes with a good powder coat. Never the less I noticed that a lot look really rusty when they come off so I applied 2 coats of hammerite and also I will wax oil once installed.
Winch also re painted in Hammerite to reinforce the manufacturers paint
[/url]Discovery 4 3.0 HSE 2010 year. I like it a lot. Now with winch 😂
23rd Dec 2018 8:14 pm
charlietortoise
Member Since: 29 Oct 2011
Location: Staffordshire
Posts: 502
New winch on D4
I had a second hand Lodar remote and I wanted to copy off other installations on here, so bought a similar electrical box. I had to cut the webbing out of the box at the back to allow the solenoid to be as far back as possible.
I mounted the box the the bracket plate with two stainless steel bolts. Then I mounted the winch solenoid into the box but I took the two bolts directly through the box and into the plate. That way the box isnt taking any load at all.
Worth noting that the lodar circuit board is actually quite bulky. So if I were to do it again I would move the solenoide as far to the left as I could. As it is for me the lodar circuit board has to slot in a particular place with the gubbins either side of the solenoid.
I used gaffer tape to hold it whilst I worked out the exact position.
Discovery 4 3.0 HSE 2010 year. I like it a lot. Now with winch 😂
23rd Dec 2018 8:22 pm
charlietortoise
Member Since: 29 Oct 2011
Location: Staffordshire
Posts: 502
New winch on D4
I puzzled how to mount the lodar circuit board. In the end I cut out the part of the box that had the mounting lugs on, drilled out 4 holes in the lid, pushed the lugs through and glued it down. Then mounted the board back to its original lugs. Seems ok.
I am a bit slower now than when I was young so it took a while to work out all of the wire connections. Anyway this is the colours and what they do
Click image to enlarge
Discovery 4 3.0 HSE 2010 year. I like it a lot. Now with winch 😂
Last edited by charlietortoise on 25th Dec 2018 11:30 am. Edited 5 times in total
23rd Dec 2018 8:27 pm
charlietortoise
Member Since: 29 Oct 2011
Location: Staffordshire
Posts: 502
New winch for D4
I had a full winch rig off my D2, so wanted to reuse the cables instead of buying new, they are pricey!
So I consulted my friend who designs switching systems for industry. And the result was some joining crimps.
I made the crimp then also soldered it. I am
a bit concerned about it but maybe it will be ok. I bought some special heat shrink, its thick and also has a glue inside of it. First one made up the insulation, then a second one on top should bulk up the insulation and water proof it.
Finished job
Discovery 4 3.0 HSE 2010 year. I like it a lot. Now with winch 😂
Last edited by charlietortoise on 23rd Dec 2018 11:55 pm. Edited 1 time in total
23rd Dec 2018 8:35 pm
charlietortoise
Member Since: 29 Oct 2011
Location: Staffordshire
Posts: 502
New winch on D4
Next job is to fit this winch isolator Solenoid
Into the engine bay here.
This has a really high amp load limit and will be turned on and off by the Lodar controller.Discovery 4 3.0 HSE 2010 year. I like it a lot. Now with winch 😂
23rd Dec 2018 8:41 pm
charlietortoise
Member Since: 29 Oct 2011
Location: Staffordshire
Posts: 502
New winch on D4
This is the overload cut out for the winch. It is a bit troublesome as to where to fit it, it wont go directly on the terminal as it sticks up too much to put the lid over it. Need to think it through a bit.
Discovery 4 3.0 HSE 2010 year. I like it a lot. Now with winch 😂
Last edited by charlietortoise on 25th Dec 2018 11:31 am. Edited 2 times in total
23rd Dec 2018 8:52 pm
OJ
Member Since: 01 Oct 2017
Location: Loch Leven
Posts: 725
Looks good so far
23rd Dec 2018 9:01 pm
dorianwoolger
Member Since: 11 May 2018
Location: Tangmere
Posts: 223
Following with intrest as planning on fitting mine very soon.
Member Since: 27 Feb 2016
Location: Perth
Posts: 204
Hi Charlie. When you joined the wires with the crimp, you say you soldered it. Did you also actually physically crimp/clamp it? Solder helps a joint to be more electrically efficient but is not designed for high current solutions where heat becomes involved. Solder should not be used as a source of physical constraint but complementary to crimping, twisting etc. Just some advice 👍
24th Dec 2018 9:02 am
charlietortoise
Member Since: 29 Oct 2011
Location: Staffordshire
Posts: 502
New winch on D4
Hi, yes it was all crimped first, I also pushed the wires right into the crimp so the ends were touching inside. The solder was a belt and braces. Thanks for the heads upDiscovery 4 3.0 HSE 2010 year. I like it a lot. Now with winch 😂
24th Dec 2018 10:36 am
charlietortoise
Member Since: 29 Oct 2011
Location: Staffordshire
Posts: 502
New winch on D4
Just a small job today. Making the bracket to mount the winch cut off solenoid.
From this.
To this
Then it fits like this
I was a bit worried as it is quite close the the FBH exhaust. If you look there are a lot of plastic parts and wires close to it so I thought I would check the heat generated
This is before the start of the cycle
after 15 mins = 80 degrees C
And just before the end of the 30' cycle. 90 degrees C
So it seems to be ok but maybe I will wrap the exhaust with exhaust heat shielding like on a motorbike. Anybody have any experiance of this?Discovery 4 3.0 HSE 2010 year. I like it a lot. Now with winch 😂
24th Dec 2018 3:47 pm
charlietortoise
Member Since: 29 Oct 2011
Location: Staffordshire
Posts: 502
New winch on D4
I am fitting the Winch controller wander lead as back up to the lodar system. I found this natty little clip assembly moulded into the air filter box.
So I thought it would be a good point to mount the socket for the wander lead.
Discovery 4 3.0 HSE 2010 year. I like it a lot. Now with winch 😂
24th Dec 2018 5:01 pm
PCT3
Member Since: 13 May 2017
Location: Kent
Posts: 144
Look as if your doing a good install, impressed that you have installed an isolating relay, not many of them around especially the ‘professional’ installs. I dislike radio systems for there reliability problems and delays in operation although Lodar are a lot better than most, not sure how the Lodar operates the solenoid but I do know you need a power and an earth for operation of the solenoid, if you where to put a simple switch to break the circuit of the solenoid, I used quad bike/ jet ski safety lanyards on the earthing wire, this will give you an idiot proof safe isolation, bit belt and braces but I have been in the vicinity of winches continuely running and isolating switches far out of reach.Discovery 3 HSE 07
Discovery 1, Search & Rescue SE4x4 Responce
Fiat Decato motor home
Mazda MX5
24th Dec 2018 5:38 pm
charlietortoise
Member Since: 29 Oct 2011
Location: Staffordshire
Posts: 502
New winch on D4
Thanks for idea, I was puzzling about what to do as an ultimate cut out switch. I think the kill cord is a very good way to do it. Proven operation and water proof as well!Discovery 4 3.0 HSE 2010 year. I like it a lot. Now with winch 😂
24th Dec 2018 5:43 pm
charlietortoise
Member Since: 29 Oct 2011
Location: Staffordshire
Posts: 502
New winch for D4
So today I was looking for an ignition controlled fuse to tap into for the winch. A bit of on line research showes F7 as a likley source and it is. It shows a symbol which I take to be cruise distance keeping? and there is no fuse in the slot. If you look carefully I can see 1 fuse spade? terminal in place and this shows as a 12v ignition controlled connection, then the other side of the fuse connector is empty.
My plan is to fit a terminal into the empty slot and connect up with a fuse. A question,
does anyone know what size/specification connector I can buy to fit in this spot?
Thanks in advance.Discovery 4 3.0 HSE 2010 year. I like it a lot. Now with winch 😂
Last edited by charlietortoise on 19th May 2019 6:24 pm. Edited 2 times in total
You cannot post new topics in this forum You cannot reply to topics in this forum You cannot edit your posts in this forum You cannot delete your posts in this forum You cannot vote in polls in this forum
