Koenig winch new clutch

I am fabricating and installing a new clutch control for a Koenig pto winch and thought I would post some pics. I am working on posting pictures so you may have to bear with me a little![/IMG]

 

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I will post more pictures and a writeup if their is any interest. I have posted all the pics in my album.

 

You bet I'm intersted. I always like new ideas and builds. Lets see how it works.

Bryan

 

Will work on getting more info on here today. Teaff is a member on here and happens to be my superintendent as well. He and I have been in collusion on this project. We are designing a tension roller to hold the cable tight to the drum right now. This winch is on a 66 CJ5, should I have posted in a different forum, like the build fabrication forum?

 

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I wanted the lever to be locked in neutral to prevent accidentally engaging the pto and winding up the bumper! The existing spring loaded pin was used to lock the lever thru a 5/16" flat washer welded to the lever arm. The shift collar is a 3/4" wide piece of 2 1/2", schedule 40 pipe. It has just enough clearance around the sliding sleeve on the drum shaft. We drilled and tapped the pipe for 1/2" coarse threads and have 1/2 nuts to lock the set screws in place. The lever and pivot rod are 5/8" round stock, these pieces came from a shock absorber stem!

 

I have all of this drawn up in AutoCad so I can share the details in cad of pdf if anyone is interested.

 

That looks very practical. I have that exact winch but have never used it. It looked to me like they had tried to wind the bumper up on mine several times. They had a roller fairlead on mine that was destroyed. I will keep this in mind when mine goes back together.

 

I didn't get before pics, but we rebuilt the rollers on my fairlead and drilled and tapped the bushings for a temporary grease zerk on each end. I am going to install the zerk to grease them then remove it for day to day jeep drivin'. Having a little trouble with posting pics right now but will get them up in a bit.

 

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We had to build a new roll and shaft for the top roller on our fairlead. But they are easy to build, 1 1/4" OD x 1" ID dom tubing, and we reused the original bushings and a new piece of 5/8" cold rolled round stock. I will post a pic a little later, don't have that one in the file.

 

, a sneak preview of the cable drum tension roller we are building for the Koenig!

 

Nice Job!!! looks like alought of planing went into it. good craftsmenship, I'd like to buy one for my winch! email sent to ya. Rusty

 

Yeah, Probably technically should have been posted on the build forum but thats ok we could always move it. Have you used the winch yet? I am interested as well. It looks like a good idea. You may have to build more than one by showing that to all of us!!!

 

I appreciate all of your feedback. I wasn't sure how many folks would be interested but I enjoy all the pics that others post so thought I should do the same when I posted. We are doing all the winch repairs at the same time being we have it all apart, so some of the progressive pictures will show the fairleads apart, the winch in place, the drum painted, etc.. Basically we are just getting it to be in good reliable condition and trying to keep it looking respectable. The task list is clutch control, drum tension roll, rebuild fairlead, new input shaft seal (SKF 8700 is the seal #) and a paint job.

 

This is a shot of the tension roll connection that Teaff built, 1 1/4" dom tubing, bronze bushings and 3/4" cold rolled shaft. We drilled and tapped the tubing and the bushing and put a set screw in each end to ensure the bushings didn't wander down the shaft. More details to post later!

 

Nice work, I too spent alot of time making a new clutch assmbly for the same koenig winch. Have you came up with the tension roller to hold the cable tight on drum. Mine is little different than yours but would like to see tensioner as I think mine needs to be changed some (hard to pull cable out, but holds cable good)
again nice work Thanks Brian

 

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We used 90 degree tension springs with 4 coils. We are still putting it back together so I can't say how much effort will be required to pull out the cable.