[ex670c]

Hi Sunil,

A mid-mounted winch is quite old and has been fitted on trucks for the past 60 years.

How ever scaling it down for a 90" WB Vehicle is a challenge.

Foers 4WD Winch

Gertrude - centre mounted PTO winch

The "Winch Challenge" vehicle normally fitted with 3 Winches.

1) Front Electric
2) Mid - PTO
3) Rear - Electric.

Regards,

Arka

[GTO]

Originally Posted by tsk1979

If you keep diesel tank inside car, how are you planning to run fuel pipes and all. Remember, fuel is volatile and dangerous. A jugaad arrangement can always blow up.
Lots of factors come into play, leakage, static electricity... the list goes on.
Even big companies with millions in R&D can get it wrong sometimes, and here you are going random with such critical stuff.

While I don't agree with the way that the winch is being installed, placing a diesel tank inside the vehicle should be the least of his worries. My Classic's tank sits under the front passenger seat and is fairly exposed. No smell, no leaks and certainly no danger (period).

I might add that diesel fuel simply doesn't have the overwhelming smell of petrol. My Jeep was pretty much unbearable with petrol in that same tank.

[hisunil]

Guys,
Finally some progress but at snail speed!!

• Soft Top is removed for replacing the top portion with brand new one
• The PTO Winch frame grinded where the Shaft will mate the Winch
• The Winch Mount is welded with supports to Tubular chassis frame & rear Bumper Tube
• 54 cms long flange with custom star-joints is being fabricated
• Ambassador connector shaft is mounted on the Winch side
• The same fuel tank will be placed inside the tub, below the rear seat, avoiding scraping it, not much alter to fuel lines & sill having space for luggage & legroom too.
• Winch was leaking Oil when filled with oil, took it to lath fixed the oil seals, applied sealant, now no leaks
• Waiting on Flange for testing on Tuesday.

Cheers
Sunil

[svsantosh]

Sunil, cant understand where the winch is located now, Can you take a pic from standing/sqatting away from the Gurkha, I am assuming it is now in the OE fuel tank location. Now, this seems good. Where is the fair lead (?) going to be mounted?

[hisunil]

SV yes it is where the stock fuel Tank was, The same Tank will sit below the Rear Seat, inside the Tub (same height & Width).

Thanks Finally to me too it looks right, but still to see if it works well. The Fair-lead will be in the rear bumper + rear chassis tube I guess. Planning to put a C or a I channel with 4 inch depth as the rear bumper, so it will be strong & the lamps can sit in side the C or I column.

Cheers
Sunil

[Sudarshan]

My guess is you are going to need 2 guides/ Fairleads ( one closer to winch drum & another on bumper ), as the winch drum is quite inside the vehicle .
Distance from the bumper/ final 'out' point ( rope delivery point ) of rope to drum seems significant .

A rope ( typical 3/8" or 10 mm steel ) under full load can cut a 16 gauge sheet or badly damage any other assembly .

Sudarshan

P.S. I will try to provide a sketch if you want it explained

[hisunil]

Guys,

Finally its Done.

Thank to Venketesh (the Garage Mech) who's persistence although slow but steadily paved the path.

We did the testing & it works like a charm.
I didn't know how long 30 mtrs was, may be I will cut half the cable.
The Shaft is Very thick & solid, the setup did Pull the Gurkha with breaks on & tied to a tree for like 10 feet.
Have wound the cable in a way that forward it unwinds & in reverse it winds & pulls, so that we can unwind it faster & winch in on load slower.
Currently no fairlead, the cable comes in between body & Chassis bar,

Will check to see what if we rout the cable across a pulley though the tubular chassis to the front, I know we cannot take the same load as directly from the back, but need to explore ways to get it out in the front next.

Time to celebrate, Will get Arun Cessata for All garage guys this week end.

YouTube - Gurkha winch shaft

YouTube - Gurkha winch wind initial

YouTube - Gurkha winch wind

YouTube - Gurkha winch w 461

YouTube - Gurkha winch

Cheers
Sunil

[hisunil]

Hi Gurkha is Back (My B-Day Gift).

Going to test the winch tomorrow, any one interested can join.
6:45 AM post hebbal flyover is the start point, a short OTR in a lake bed nearby & should be back by 11:00 am.

Apologies for the short notice, but things just shaped up.

Cheers
Sunil

[SPIKE ARRESTOR]

Hisunil, is that the fuel line passing through the body floor panels? If yes, at-least use a grommet near the interface, you never know... Be safe!

Spike

[hisunil]

Yes Sure will do, lots of refinement to be done a various places. Would like o change all he fuel lines.

Thanks
Sunil

[hisunil]

Hi Guys,

Had some fun & frustration this Sunday.
The 4wd liver got stuck in neutral while testing the PTO, so Me & Fred tried calling Force Mech, who advised to pull out the 4wd GB handel & reset it.
we tried that for quite sometime, but in-vain. After Fred left & while waiting for the Mech,
My Bro arrived in his gypsy & we trying to remove the allen key bolts hold the 4wd GB liver in the processes, realized that the GB pops an axil (on the side of the GB) below the vehicle for every 4wd gear change,
so got below it & punched the axil in side and releasing the GB!!

Later we tested the winch in quite steep slope, it works great. during the 3rd trial the cable snapped as it wound outside the drum. I sure need a fairlead immediately.
Poins observed.
It can take Tons of load
No slippage of gears
12 mm steel cable is the week link (PTO GB, Shaft, Drum all else are really strong).

[video=youtube;D6aH4bgQExw]

[hisunil]

The PTO winch was put to Good use, more detailed video's in north-pinakini-riverbed-recce-22nd-may-2011
Couple of them worth mentioning here are :

YouTube - ‪Winch Sand Recovary‬‏

Caution Long video, needs patience (esp if the www link is slow)

YouTube - ‪Water Recovary long‬‏

The toe hook recovery didit budge, I was sinking in trying to pull, when we tried to cater-pill with the toe rope, the toe hook assembly broke in the stuck vehicle & Lucky the flying cable did not end up hurting any one or my front glass, you can see it in the below video:

YouTube - ‪Toe Hook Snaches‬‏

Finally the TANK Crawls by itself steer-by-self

YouTube - ‪Gurkha Crawls by itself‬‏

Cheers
Sunil

[hisunil]

Guys The Bumper & Fair lead is DONE

Rear bumper:
10mm thick, Gas welding cut, hydraulically bent

Fair-lead
Solid pulleys for horizontal restrain
Solid metal bars for vertical restrain













































Cheers
Sunil

[hisunil]

Just tried some small rock climb for my cousins who had come down for Bro's house warming ceremony

IMG 2626 - YouTube

The Water pump being tested on PTO, will be fitted next week.

IMG 2639 - YouTube

IMG 2640 - YouTube

IMG 2641 - YouTube

IMG 2642 - YouTube

Cheers
Sunil