*originally posted in…… wait…. it’s ALL NEW! Hehehe!*
You guys remember that I talked about adding a winch system to the trailer just in case the car is disabled and cannot be loaded on its own power. I didn’t want to go half-assed into this so I made a complete package plan. Starting with a protective box (from the elements and theft). Here’s all the parts for it previously cut and prepped:
I then needed a chest to store all sorts of stuff like straps, etc, and to contain the winch junction box and wires. I was lucky enough to find a DELTA chest at 50% off (clearance sale). That meant that fabbing one myself would not have been worth my time. Here it is installed alongside the winch:
If you noticed, I’ve also added a L-shaped strip over the wood plank’s screws that the winch is bolted into. That will prevent the plank from shearing off under winch stress.
To further protect it from the elements, I’ve added a simple rubber piece with a “X” cut into it to allow the winch cable to move freely every which way. There was also the need to be able to access the winch’s locking gear to allow for free-spool and engaged mode selection. Here’s the whole box welded up and installed:
Then was the matter of wiring the winch up properly. I’ve added a 20 feet cable to allow me to power the winch straight from the pickup’s battery while the engine is running. I did not want a heavy battery taking up space in my chest.
As you saw, I did lay a nice rubber mat in the chest to help reduce noise and vibrations. Multiple theft prevention measures were later added but I will not show them.
The chest, even if it seems large and protuding, does not prevent tight cornering at all. There’s a 3 inch gap from the rear bumper when at a 75 degree angle… which you never get under normal circumstances.
The rear tie-down rings I had previously installed were reversed… they work better this way:
In my recent trips with the trailer I noticed some flexing of the tongue beam which I did not like. Just to put my mind at ease, I bought a 2.5″ square aluminium tube which I slightly ground, polished, and greased up to sledgehammer it into the tongue beam:
Looks easy enough, right? Try to imagine to wedge a 7 foot long beam into another one tightly… No, it was not that easy! However, it is done and the overall thickness of the tongue is now 7/16″ instead of 1/4″. I could feel the difference straight away.
Did you notice something else in the last pic? Aye, I’ve added a nifty holder for the trailer plug when not coupled:
The only thing really left to add to this trailer is a spare tire mount. That will come later. For now, I simply throw it in the pickup’s bed when I use the trailer…