Member Since: 22 Feb 2013
Location: Northants
Posts: 889
Spare wheel winch mod write up finished
Spare wheel winch modification
This write up explains the making and installation of my spare wheel electric winch mod.
Please accept that there may be mistakes in this write up and it may not be perfect.
So, the problem, a full boot, in my case a huge dog box and shooting equipment. To access the spare wheel winch the boot would need to be emptied and the rear 3rd row seats lifted.
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This mod enables the spare wheel to be lowered and raised without the need to do this.
Parts used are as follows.
• A slim line, high torque electric sunroof motor.
• A 22mm impact socket (modified to fit)
• Alloy or steel plate for fixing to the boot floor
• A double pole carling switch, plug, connectors and housing plate
• Various cables, 1.5mm should be fine as this is rated at 19amps 2.5mm or 4mm is better and that’s what I used up to the switch from the supply.
First thing is to measure up the plate, you can use any measurements doesn’t really matter, as long as the end result is the same. Mark out the hole in the centre for the socket to pass through, I used a 32mm hole for clearance.
Next you need to modify the impact socket, I used a lathe and turned down the socket to a suitable then turned out a recess to take the spline of the motor shaft, this needs to be exact as not to throw off centre and put increased torque on the motor. Motors will vary.
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Test fit and then weld the impact socket to the shaft. Place the steel or alloy plate over the hole and lign up the motor assy. Mark out the holes to fit, I drilled through the housing and then drilled out the plate, screwed up from the bottom.
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Now drill holes along all sides of the plate for fixing to the floor, I used wide thread carpet screws as I didn’t want to screw into the metal floor, I found this quite adequate.
Carpet the plate for asthetics.
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Test run the motor before fixing the plate and it will fid its own centre, be mindful that if you have wrenched the pulley up you will need to loosen it off first with a spanner.
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This will also prove that the motor you have chosen is man enough to wind up and down, if you have one put an a dc clamp meter like this and check the run up/down and stall amps.
Mine proved to be between 3 and 8 and about 15-18 on stall.
Then remove and test the tightness when up, ultimately it needs to be tight but it seemed to be fine in my case.
You can now screw the plate to the floor and that’s pretty much that bit done.
I painted mine up and intend to cover it over in time.
Route the cables up to where ever you want the switch and wire as per the diagram instructions, or to the instructions of your own switch. I drew them in a hurry and as a result I got the pins wrong in the drawing, the actual numbers are correct though. I used a 20-amp fuse but I may need to go slightly higher. I will prove this later on in the end testing.
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Cut a hole for the switch and then run your cables to the battery, a bigger fuse can be placed at the battery to protect the cable, i.e. 30 or 40 if using 2.5 or 4mm cable. Tap off the courtesy light feed to supply the switch illumination.
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Once wired in you can put the seats down and test that your switch works as it should, i.e. up is up and down is down.
Trying to video, push the button and level the wheel was too tough, so I apologise for the painfull video.
You all get the idea tho.
That’s it really, I apologise if I’ve missed any thing but feel free to ask questions if you’re going to do this your self.
Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated You remind me of a younger me, not much younger mind...perhaps even a little older!
24th Jan 2014 4:51 pm
waterbuoy
Member Since: 26 Oct 2013
Location: Argyll
Posts: 2909
Excellent - I guess you must be the only person ''wanting' a puncture now Currently 2009 Disco 3 SE, 2013 MY D4 HSE and 2016 D4 SE
Previously:
TD5 Defender 110 CSW (230k miles)
300TDi Disco 1 (289k)
4 RR Classics (300-350k each, 2 manual, 2 auto)
110 V8 CSW (220k)
S3 109 hi cap pickup (ex RN)
S2A 88 Safari SW with lpg conversion (bloody lethal)
That's a nice write up Steve, will you offering this as a supplied mod..? I for one would be interested as my G4 is forever laden with expedition or recovery kit and I also have a full length load barrier, so taking it all out to lift the 3rd row seats would be would be a PITA!!G4OC Secretary
N44RT Callsign NH89
24th Jan 2014 5:36 pm
sasdiscos
Member Since: 22 Feb 2013
Location: Northants
Posts: 889
Im not sure if i will be making these, I don't know if i have the time, ill cost it up and see, its simple enough to do.
As for wanting a puncture thats the story of my life, plain unlucky me.You remind me of a younger me, not much younger mind...perhaps even a little older!
24th Jan 2014 6:30 pm
wiggs
Member Since: 03 Sep 2006
Location: Manchester
Posts: 14372
Nice
What car did you acquire the sunroof motor from ?G4 Gone ...but not forgotten
24th Jan 2014 6:31 pm
StephenO
Member Since: 15 Feb 2010
Location: Scotland
Posts: 1652
Impressive 2016 RR Sport Autobiography
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24th Jan 2014 6:38 pm
sasdiscos
Member Since: 22 Feb 2013
Location: Northants
Posts: 889
its a merc w124 motor, its a bosch.
SteveYou remind me of a younger me, not much younger mind...perhaps even a little older!
24th Jan 2014 6:39 pm
01coccobet
Member Since: 23 Feb 2009
Location: on air
Posts: 2624
Great writ up
figuring it out!!!!
the best feeling:getting airborne.
I'm sure there is a market for these, either complete or as a kit. If you dont fancy doing it yourself, perhaps there is someone else on the forum who might take it on.A vaccine does not stop you catching a virus, or passing it on, or getting ill from it, really ill. It does reduce the likelyhood of you dying when really, really ill. Stay Alive - KEEP AWAY FROM PEOPLE.
18th Feb 2014 3:52 pm
sasdiscos
Member Since: 22 Feb 2013
Location: Northants
Posts: 889
Maybe, but the tread doesn't seem to have gained much interest, so it's a dead duck by the looks of things.You remind me of a younger me, not much younger mind...perhaps even a little older!
Most odd - considering the number and size of the posts about duff winches.A vaccine does not stop you catching a virus, or passing it on, or getting ill from it, really ill. It does reduce the likelyhood of you dying when really, really ill. Stay Alive - KEEP AWAY FROM PEOPLE.
1st Mar 2014 10:27 pm
wiggs
Member Since: 03 Sep 2006
Location: Manchester
Posts: 14372
Iv tryed two merc sunroof motors .. And a honda door winder .. Non will bring the wheel back up
Could be that its a big grabber AT ?G4 Gone ...but not forgotten
1st Mar 2014 10:31 pm
sasdiscos
Member Since: 22 Feb 2013
Location: Northants
Posts: 889
Hmm, could well be. Needs 14 volts not 12 I found.You remind me of a younger me, not much younger mind...perhaps even a little older!
2nd Mar 2014 7:09 am
Chillb
Member Since: 14 Feb 2013
Location: Portsmouth
Posts: 68
Very clever
2nd Mar 2014 8:18 am
Bodsy Site Sponsor
Member Since: 06 Nov 2006
Location: In the Clubhouse
Posts: 21361
That's a really neat way of doing it.
I'm not sure you should be put off by lack of comments, you've got it all sorted, comments usually come when you ask for an opinion on how to do something, rather than a completed, clear write.
I think it looks ace and a great solution to that problem. Bodsys Brake Bible
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