gearmatic winch roller fairlead build

notmeu · Post by **notmeu** » Fri Nov 27, 2015 3:35 pm

Hello all, I'm in the process of building a set of four roller fairleads for on my 8a winch fitted to a 420. I am going to build it using 1/2"x3" flat steel as seen below.

Where the 2 spray paint cans are that is where the 2-1/2" solid steel rollers are going to be located, same location for on the top. I am going to turn the ends down to 1-1/2" and weld a greasable bushing onto the 1/2"x3" plates. There is going to be 1/2"x2" flat plates for support around the rollers to tie everything together to make it ridged.

My question is for anyone that has roller fairleads on their winch, is there anything you would of added or moved or wished it had to make life easier?

I have 5/8" cable that I will be putting on the winch very soon with a swivel hook on the end. I also have some cat chocker's that will attach to the swivel hook.
The winch will be used for logging more than anything else. Any input would be appreciated!
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pop pop · Post by **pop pop** » Sat Nov 28, 2015 11:36 pm

i would make the rollers bushings longer but then i would do other things differently too, so just build it .

notmeu · Post by **notmeu** » Sun Nov 29, 2015 3:49 pm

pop pop wrote:i would make the rollers bushings longer but then i would do other things differently too, so just build it .

Pop pop, how long are the roller bushings from the factory? I was going to make mine a inch long. And yes, I'm going to build it.....

Post by **Lavoy** » Mon Nov 30, 2015 9:15 am

In the 2" range, I have a roller here I can measure if you need.
Lavoy

Post by **Lavoy** » Mon Nov 30, 2015 9:17 am

Forgot to mention, I have a few frames done, but striking out on rollers. I can give you dimensions on the OEM vertical rollers if that helps. I would be interested in some rollers to complete the fairleads I have.
Lavoy

notmeu · Post by **notmeu** » Mon Nov 30, 2015 5:54 pm

Lavoy wrote:In the 2" range, I have a roller here I can measure if you need.
Lavoy

So your saying the rollers are in the 2" range? I have 2.5" solid round steel to be used as the rollers, ready to be turned down on the lathe to 1.25 on the ends only for the bushings that are going to be 1" long. I would think that would be plenty of over kill??? What do you think lavoy?

Post by **Lavoy** » Mon Nov 30, 2015 9:29 pm

Rollers are about 2 1/2" if I remember, but will have to measure one. They are thick wall tubing, no need for solid stock, cuts down on weight and easier to work with.
Lavoy

notmeu · Post by **notmeu** » Tue Dec 01, 2015 6:06 pm

Lavoy wrote:Rollers are about 2 1/2" if I remember, but will have to measure one. They are thick wall tubing, no need for solid stock, cuts down on weight and easier to work with.
Lavoy

Thanks lavoy, I thought that weight was a dozers best friend!!!

I already have the solid bars just about ready to weld. Hopefully it is not too much weight for the mounting plate. I may tie it into the FOPS to help distribute the weight.

Paul Buhler · Post by **Paul Buhler** » Tue Dec 01, 2015 7:49 pm

Tom: In the scheme of things your rolls' weight isn't going to be an issue. From memory, I think that the vertical rolls on an integral winch arch we're hollow with sealed bearings inset top and bottom. There was an axle that ran through the whole assembly held in place to the arch by a small dogged top plate, and a cotter key at the bottom. I bet that your rolls never bend. My winch does'nt have the top outboard bolt housings any more. The winch cable, when used for diagonal pulls, wore them away. By making your fair leads, I'm pretty sure that you're extending the life of your winch housing and cable. I think that your greased bushings will work well. Keep us posted. Paul
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notmeu · Post by **notmeu** » Sat Dec 05, 2015 5:22 pm

Well I finally found some time today to get one roller mounted and spinning without any drag. Here's a photo of how the solid roller was turned down to 1-1/4" to fit in the bushing that is welded to the 1/2" plate.

I installed a grease fitting into each end of the bushing and the fitting is protected by the bushing.

1 down 3 to go!

Paul Buhler · Post by **Paul Buhler** » Sat Dec 05, 2015 10:31 pm

Looking good. Keep the pictures coming. I'm curious to see how you tie the whole assembly together.

notmeu · Post by **notmeu** » Sat Dec 12, 2015 8:34 pm

Well about 30 hours into the fairlead build and both the side rollers are welded in their home position with a piece of 1/2" x 2" flat plate and a piece of 3/8" x 2-1/2" flat plate surrounding the upright roller to protect them and help stiffen them from twisting. I only have the top and bottom roller weldments to go and then add another 1/2" x 2" flat bar on the top and bottom to tie the top and sides together. I made the horizontal roller mounting plates slightly curved so they rest on the winch housing to try and relieve some of the stress against the fairlead frame, if it ever requires it. Getting close to the end, then back to adjusting the winch clutch and brake and put her to work!

Paul Buhler · Post by **Paul Buhler** » Sun Dec 13, 2015 3:16 pm

You do nice work. Let us know how it works. How many sliders do you plan to use?

notmeu · Post by **notmeu** » Sun Dec 13, 2015 3:54 pm

How many sliders do you plan to use?

Actually Paul, I did not figure on using any sliders yet, I have a swivel hook to put on the rope, then I have 3 cat chokers I planned on clipping onto the hook once roped around the tree. I hope it works without tangling too much. If it doesn't work go well, I'll try the sliders. I also have 2 older heavy duty wheel barrels that I'm going to make into logging sleds. I think the combination should work out......

Paul Buhler · Post by **Paul Buhler** » Sun Dec 13, 2015 6:21 pm

Hey, what ever works. I set up my winch based on what I was taught, and I know that there are other ways of doing things that are equally valid.

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gearmatic winch roller fairlead build

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