Reserve Winch

The reserve winch is a German TOST 04 model winch. SSS obtained the winch from the RAFGSA with it mounted on the back of a converted Bedford Bus. Due to increasing reliability problems with the bus, during 2012 the winch was removed from the bus chassis and installed onto a custom made trailer chassis.

Engine

When the club originally obtained this winch, it was fitted with the Oldsmobile 455 engine that is now fitted to the Skybrid winch. The 455 was removed when the crankshaft broke. It was replaced with an Oldmsobile 403, which though wasn't as powerful as the 455, proved to be a good winch engine. Unfortunately, this engine threw a con rod, and so was replaced with a Pontiac 400 (The club's winches are both fitted with GM TH400 which are available with two different bell housing patterns - Chevy style (five bolts) and BOP (Buick, Oldsmobile, Pontiac) style - 6 bolts. This means that the club tends to use Oldsmobile and Pontiac engines (we haven't tried Buicks yet!). Click on this for more data on the Pontiac 400.

Trailer Chassis

The trailer chassis was designed (by James Hunneman) in a similar manner to the Skybrid winch's trailer chassis to allow similar ease of access to the winch mechanical parts, ease of towing and to cater for winch upgrades in the future. The trailer coupling, hitch stand, wheels, tyres and LPG tank are all the same. The axles are made by the same manufacturers to similar specifications, although the axle bracket's positions are in different positions.

• Trailer coupling: Bradley HU12 Cast Delta Coupling. Auto-reverse. 2200-3500Kg capacity
• Hitch stand: Same as that used on Skybrid winch. Obtained from Skylaunch.
• Trailer axles: Custom made and supplied by Peak Trailers. Bidford-On-Avon. 1500Kg axles, 200x50mm brake size, 5 stud on 6.5" PCD, M16 stud pattern (This is the Land Rover wheel stud pattern-deliberately chosen for ready supply of wheels and commonality with Skybrid winch). Peak Part Number: RA15B200A565. Dimensions O.H.F.=2367mm, Cut length=2065mm. Twin sets of axle brackets fitted at 1950 & 723mm centres. 4-hole cable anchor plate welded to top of axle. (Price was £250+VAT for each axle) Peak Trailers +44 1789 778 041 Peak Trailers
• Wheels: Land Rover Defender SWB rims. Size 5.5J x 16" ET 33mm offset. 5 stud on 6.5 inch PCD. These rims are readily available secondhand or new. A set of five Land Rover wheels with good Michelin 205R16 tyres was obtained for £100.
• Mudguards: Obtained from Peak Trailers. Part Number TSM867. 8"x67". They're not the best or straightest steel pressing in the world, but they only cost £65.
• LPG tank: A new tank and fittings was installed. The same make and type as fitted to the Skylaunch, obtained from a very helpful company called TinleyTech Tinley Tech +44 (0)1767 676181. The tank used is a 4-hole Cylinder Tank 360x892mm 80 litre capacity. With valves this cost £199+VAT. Also purchased was an Optical level display, a tank frame, and a remote ACME-JIC filler. A new gas-shut-off solenoid was fitted to the tank itself, and the original winch's one removed, and the wiring extended to the tank solenoid.

The trailer bolts to the TOST winch using the TOST's standard four mounting holes (basically, one M14 bolt in each corner). The axles were positioned such that there was a little hitch weight but not too much. If future winch upgrades modify the winch's centre of gravity, there are alternate mounting holes pre-drilled in the lower face of the trailer chassis to allow moving the axles to compensate. (Though the mudguard brackets would have to be cut from the winch)

• The trailer was designed so as not to prevent the future fitment of Skylaunch's large diameter steel drums (These have the advantage of doing away with the cable paying-on gear)
• The elevated platform is designed such that it could be used as the base for an enclosed cab if one is wanted in the future.
• James Hunneman has full Solid Works CAD models and drawings and a build manual and parts list for the winch trailer.

At the same time as the trailer conversion, some other work was done to the winch:

• The original front fibre glass moulding was replaced with a protective grill.
• a new centre piece for the engine cover was manufactured and the hinges and folding panels refurbished.
• The winch frame and panels got a coat of paint.
• The back of the cab was reworked to permit easy access and a new seat fitted. A weather guard was fitted for the radio (but could do with being re-thought and made better...not my best bit of design-JH!)

Spring 2019

Following the catastrophic failure of the Skybrid winch and the near loss of launch capability for an indefinite period, the directors elected to seek a quotation from Skylaunch to complete the reserve winch as a fully serviceable winch.

Parts Replaced/Work Done

In Sept 2012 while the winch was being re-commissioned it was discovered that the sump contained 14 litres of water as well as the usual oil content. No explanation for this could be found. The engine was drained without being run, refilled with oil and fitted with a new filter. The engine was run for a short period and the inevitably sludgy oil drained. It was refilled with a flushing mixture, run at operating temperature, drained and refilled with fresh oil and the filter changed again. After running for a while the oil was checked and found to be clean. The radiator shroud was adjusted having been found to be fouling the fan. After refitting, having been 'borrowed', the starter motor started making 'binding' sounds, even though the original shims had been refitted. Various shimming arrangements did not improve matters, so it was decided to go with the original shims and keep an eye on the condition of the flywheel ring gear.

The drum brakes were adjusted and the wooden cable guards realigned.

The engine oil subsequently remained remarkably clear and the starter gave no further cause for concern.

26th September 2019

JH completed necessary work on winch controls and safety cage to undertake preliminary trials. First launch was Puchacz HCF flown by CB. That and several subsequent launches with single seaters were completed successfully and without incident. There is a potential issue with the prop shaft that needs to be monitored (angle of offset and wear of u/j bearings.

End Aug 2017

The winch is well on the way to becoming serviceable following a strategic plan by James Hunniman. Following Ken Hansell stripping off the cab and paying in gear, the chassis has been rebuilt by Peter Ellison to accommodate larger drums. The cab base frame has been reconditioned by Colin Baines, with a new floor. A tipping cab frame has been fabricated, also by PE. The reconditioned differential has been reassembled to the original selector boxes by Bill Cook and mounted on the chassis with new strengthened half shafts and roller bearings. Both selector mechanisms have been reconditioned by CB with new dog clutches. The new Skylaunch big drum has been fitted. Both guillotine assemblies have been rebuilt by CB and inverted as per the Skybrid conversion. A new guillotine operating mechanism has been designed, fitted and tested - also by CB. A Skylaunch sprung roller box has been modified and positioned by CB/KH so as to provide correct feed into the new large drum. A new, more powerful transmission oil cooler has been fitted by CB. The gas system has been moved and refitted by JH. The electrical system has been completely rewired by CB, new plugs and oil pressure sender unit fitted, the engine started and all existing systems tested. Trevor Greenwood aided by Paul Bryant is repainting everything as it is assembled. A reconditioned starter motor has been fitted.

The winch will be ready for load testing pending JH completing the disk brake operating system and PE building a drum cover.

(Names of contributors have been included for future reference as few build drawings exist.)

Drawings - such as exist:

Wiring diagrams Media:Electrics.jpg‎ Media:Wire_capacity.pdf

Drum cover Media:Drum_cover_2.jpg

Brake lever plate Media:Brake_lever_plate.jpg‎

Guillotine link Media:Guillotine_Link.jpg‎

End Dec 2015

I was decided at the AGM to rebuild the RW as a single large-diameter drum (Skylaunch style) winch, but with further thought it was decided to rebuild it as the club's main winch, making it a twin drum winch by appropriating the running gear from one side of the Sykbrid winch. As of this month the winch has been stripped down to a bare chassis with only the engine and gearbox remaining in situ. A replacement differential and half shafts have been acquired from Skylaunch and a large cable drum is on order from Skylaunch.

End Dec 2014

Differential self destructed. Inner half shafts cannibalised to repair Skybrid. One outer half shaft key way stripped. Not economically repairable.

Dec 2014

• Engine blowing out dipstick - cleaned breather system

Jul-Oct 2014

• Having fitted a new left-hand master cylinder it was discovered that the right hand one had also seized. Consequently the winch is now fitted with two new 0.625 bore Girling brake master cylinders.
• The winch is fitted with a GM TH400 automatic gearbox which is locked into a single gear as per original Tost design. This gives 12kt/100revs and causes the engine to hit the rev limiter in light headwinds.
• Releasing the cable under tension WILL cause winch drum snarl ups.

February 2014

• Engine Misfire - changed plugs and leads.
• Left hand drum seized possibly due to faulty brake master cylinder. Master cylinder not releasing pressure. Removed MC checked breather hole and shortened push rod to ensure free play and backed of cam adjusters. Rebuilt and tested OK but then started seizing again.

Hello Colin,

The U/S master cylinder I removed from the winch had a bore of 5/8" or 0.625" The mounting holes are 2.25" between centres. At the time we had the issue, I couldn't find a master cylinder with the same bore for less than £60, so I took a gamble on the 3/4" bore master cylinder (Land Rover clutch £8.50!) working - and it did work when I first built it up. Perhaps as things have bedded in something has changed?

Anyway, a quick ebay search for 0.625" master cylinders shows that there's now quite a lot for sale: http://www.ebay.co.uk/sch/i.html?_trksid=p2050601.m570.l1313.TR0.TRC0.H0.X0.625%22+bore+master+cylinder&_nkw=0.625%22+bore+master+cylinder&_sacat=0&_from=R40 This one might be suitable: http://www.ebay.co.uk/itm/Integral-Brake-Master-Cylinder-0-625-Kit-Car-Cortina-etc-/161231939056?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item258a2c25f0

Worth checking that I'm right, because I'm in a bit of a rush. If the brake union thread is metric instead of imperial or vice versa, I have a flaring tool to make up a new pipe, but I think it should just be a bolt in replacement.

James

January 2014

• Left hand brake binding, probably due to lack of use. Brake adjusted and freed off, requested winch be used on first Sunday of each month.
• Oil pressure warning light illuminating - replaced oil pressure switch - OK.

Summer 2013

• Left hand drum brake u/s. Master cylinder replaced and recon brake back plate assembly fitted.