Winch Buildup/Cleanup Thread(Updated)
 

Well as you all have seen in the other thread I picked up a HS9500i Warn Winch. It was permanantley mounted to a Jeep for two years in the lovely salt of Michigan winters so it needs help. Its heavily oxidized and the powdercoat is peeling everywhere. Just though I would post this thread as a before/teardown/paint/rebuild if anyone wanted to know what is involved.

Before
http://www.04lvl2.com/gallery/d/347-1/DSCF4146.JPG
http://www.04lvl2.com/gallery/d/369-1/Picture017.jpg

Cable Removed
http://www.04lvl2.com/gallery/d/349-1/DSCF4152.JPG

Right side end housing and solenoid cover removed.
http://www.04lvl2.com/gallery/d/351-1/DSCF4153.JPG

Motor Removed
http://www.04lvl2.com/gallery/d/363-1/DSCF4159.JPG

Inside view of the motor.
http://www.04lvl2.com/gallery/d/353-1/DSCF4154.JPG

Drum and center section.

http://www.04lvl2.com/gallery/d/355-1/DSCF4155.JPG

Solenoids
http://www.04lvl2.com/gallery/d/357-1/DSCF4156.JPG

Winch totally disassembled.
http://www.04lvl2.com/gallery/d/367-1/DSCF4161.JPG

Evan took the fairlead rollers home to clean them up. This is some before and after of them.
http://www.04lvl2.com/gallery/d/371-...e046Medium.jpg
http://www.04lvl2.com/gallery/d/375-...47Medium-1.jpg

I have contacted Warn and they have sent me new labels and emblem for it. I have new gaskets for it as well that I have to pick up from the local offroad shop.

Well here are the accomplishments of Erv and I today. I sandblasted everything in the AM and took off to his house around 1. After a can of Self Etching Primer, Two cans of Duplicolor Dark Shadow Grey and Two and a half cans of clear here is the result. Hopefully pics of it all mounted will come tommorrow. I am very impressed with how it came out.

Primer
http://www.04lvl2.com/gallery/d/377-1/DSCF4164.JPG
http://www.04lvl2.com/gallery/d/379-1/DSCF4165.JPG

Solenoid cover done. This is the only peice that I may repaint, it was the test peice, doesnt look bad but could stand to be redone.
http://www.04lvl2.com/gallery/d/381-1/DSCF4166.JPG

Roller Drum coated in leftover POR15 that Evan had.
http://www.04lvl2.com/gallery/d/383-1/DSCF4168.JPG

Everything sprayed with paint.
http://www.04lvl2.com/gallery/d/387-1/DSCF4170.JPG
http://www.04lvl2.com/gallery/d/391-1/DSCF4173.JPG
http://www.04lvl2.com/gallery/d/393-1/DSCF4174.JPG
http://www.04lvl2.com/gallery/d/397-1/DSCF4179.JPG

All components cleared. If I remember there is about 6+ coats of paint and 6+ coats of clear on everything but the motor. The motor got 10 coats or more of clear and numerous coats of paint. The cooling fins were a pain to cover. fairlead not pictured.
http://www.04lvl2.com/gallery/d/401-1/DSCF4195.JPG
http://www.04lvl2.com/gallery/d/403-1/DSCF4197.JPG

Ok its all done, looks great. I will get better pics when its light outside. Have to wire it up for the front and rear, also install the front hitch.

http://www.04lvl2.com/gallery/d/405-1/DSCF4198.JPG
http://www.04lvl2.com/gallery/d/407-1/DSCF4199.JPG
http://www.04lvl2.com/gallery/d/409-1/DSCF4200.JPG
http://www.04lvl2.com/gallery/d/411-1/DSCF4204.JPG

sweet action!

you got some work ahead of ya. looks like yer getn it done tho

Looks good, are you going to mount it to your front or how are you going to do that?

Rocky

nice. make sure to tape up the end of the motor really good and to use as little pressure as posible with the sand blaster.

Did you find the moly lube you needed.

No powdercoating for it? Would that hold up better than paint because the type of tool that it is?

I have this cradle sitting in the garage right now, actually two of them becuase one was damaged in shipping. I have a front hitch to go on and the trailer hitch in the rear.

http://www.04lvl2.com/gallery/d/373-...930015hd_w.jpg

No on the lube, I have to hit Autozone and Pepboys on Saturday and see what they got.

I am sure that powdercoat would be better in the long run but being its not going to be a permanent mount it will not be in the weather as much as it used to. I think the paint will hold up fine.

they didnt take the old mount??
tight.
i try and get some pix of the fairleads finished.

I have to call them and see what they want to do.

Are you going to put the wire cable back on or you getting the rope one?

Attachment 211139

compaired to mine
Attachment 211140
it might looks as clean as mine one day
Attachment 211141

Thanks Evan, they look alot better.

For now the wire cable is staying. Maybe in the future I will get the synthetic line.

lookin good fellas..just another thing added to the list of things done to the good ole truck

Kick ass bill, its going to look really good.

looks good man have fun puttin that thing back together lol

Nice job Evan.

Nothing to it man, its alot easier than you think

looks good bill! definatly a nice addition

Lookin good bill!!!

thanks

Very nice looks good

you got some updated pix yet damit?
i didnt spend all day workin on it and have no pix shown.

ha j/m


btw, i forgot about that snap ring that broke... we gotta get one tomorrow