See below, donāt judge!
I was hopeful it would carry the current, but alas it didnāt. Iām trying to find someone that can solder the copper to the ole copper and the brass bolt that is the terminal. That āshouldā work.
What did you do to your TJ today?
- Thread starter LJRubiconGuy
- Start date
I was hopeful it would carry the current, but alas it didnāt. Iām trying to find someone that can solder the copper to the ole copper and the brass bolt that is the terminal. That āshouldā work.
I installed a new passenger side grab handle, I got tired of the wrap around style. Since I run a safari top most of the year and using a wrap around style is a PIA as the top also wraps around the spreader bar.
So I drilled and tapped the spreader bar and made a small hole in the roll bar cover. Inserted a bolt thru the cover with a nut on the other side. I needed some way to lock the bolt in place w/o tightening it down all the way as I need to leave room for the padding. I tried this in the past but could not find a quality grab handle till this company was posted by @mrblaine
on another post. Anyway tightened everything down slid the padding back in place and wrapped the cover back around now done. Even found a black Allen head bolt so it smooth and blends right in to go along with my OCD 
So I drilled and tapped the spreader bar and made a small hole in the roll bar cover. Inserted a bolt thru the cover with a nut on the other side. I needed some way to lock the bolt in place w/o tightening it down all the way as I need to leave room for the padding. I tried this in the past but could not find a quality grab handle till this company was posted by @mrblaine
on another post. Anyway tightened everything down slid the padding back in place and wrapped the cover back around now done. Even found a black Allen head bolt so it smooth and blends right in to go along with my OCD 
Added a rear recovery hook. Got the bolts torqued down and realized I forgot the retainer clip.
Hey - you tried. It looks like it can be soldered ok - just takes lots of heat and enough flux.See below, donāt judge!
Thatās was my thought, I couldnāt find a brass screw that was self-tapping. The copper wire in the stator took an act of God to drill through. One screw was the best I could do. I may be YouTubing how to solder and learning that skill. I donāt want to shell out a ton of money on a new winch, I donāt wheel hard enough to āneedā a WARN. It would be nice to have and I may have grabbed one, but Iām looking at a 10-15k crawlspace job in the next month. There went my 2022/2023 Jeep mod budget
1. How did you connect the copper āpatchā to the new brass screw? Itās not evident from that photo. That connection will see hundreds of amps and needs to be robust. Thatās why the mfr uses a slotted hex with a swaged connection. If that isnāt a good, solid connection, it wonāt transmit enough energy for the motor to work.
2. Did your fix keep the winding isolated from the case? Itās hard to tell. Thatās why the original is wrapped In cloth/resin.
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. I just went for it with no great knowledge. I took the brass bolt and cut out a larger slot for the copper and tried to wedge in as much as possible. It was a definite āHail Maryā
I attached the copper patch with the screw, I cut off the wrap from the previous wire so the copper would make contact. I didnāt realize it needed to be insulated from the outside cover.
This was an all ānew to meā Adventure as I donāt know much about electrical stuff. Iām hopeful to find someone that can solder it together, if not Iām just going to more than likely trash the winch and get one down the road.
Replaced my injectors and the manifold heat shield
Youāre lucky it didnāt burn,but it should be repairable.. I just went for it with no great knowledge. I took the brass bolt and cut out a larger slot for the copper and tried to wedge in as much as possible. It was a definite āHail Maryā
I attached the copper patch with the screw, I cut off the wrap from the previous wire so the copper would make contact. I didnāt realize it needed to be insulated from the outside cover.
This was an all ānew to meā Adventure as I donāt know much about electrical stuff. Iām hopeful to find someone that can solder it together, if not Iām just going to more than likely trash the winch and get one down the road.
Before a trail run, checked the air in my spare tire. 9.7 pounds. Hmmmmm....probably ought to check that more often.
Well I havenāt cracked it back open to check yet either.
Iāll find someone to fix it right!
I've had winch motors repaired at shops that specialize in rebuilding starters and alternators. If you still have one around in your area I would take it there and have them look at it. The last one I took in was completely locked up and they repaired it for $70.Thatās was my thought, I couldnāt find a brass screw that was self-tapping. The copper wire in the stator took an act of God to drill through. One screw was the best I could do. I may be YouTubing how to solder and learning that skill. I donāt want to shell out a ton of money on a new winch, I donāt wheel hard enough to āneedā a WARN. It would be nice to have and I may have grabbed one, but Iām looking at a 10-15k crawlspace job in the next month. There went my 2022/2023 Jeep mod budget
Today I finished up timing gears and chain replacement, as well as a water pump replacement and radiator flush. It was a greasy ass job but after about 6 hours of working and cleaning inside the engine bay , I got her back together. My little 2.5l purrs like a walrus now. No hesitation between gears , no sputtering from cold starts, smooth idle to boot! Next job is to get the frame welded up and slap on some new brake lines. I only took a couple pictures since my hands were completely covered in grease and antifreeze but it all went pretty smooth for someone who has never been that deep in an engine before
alpineovernappa
Member
Finally got around to replacing my 170k mile stock OPDA. Was surprised that the ticking I'd associated with my exhaust manifold crack was actually OPDA related (and resolved with the new Crown unit)
