Y Winch

Introduction

The Y winch is based on the chassis of a Tost 04 model winch. This had been purchased from the RAFGSA, mounted on the back of a bus chassis. For history, and details of the trailer chassis build, LPG system, etc, see the old page which detailed the work done Reserve Winch This winch suffered a catastrophic axle failure in late 2014. Since then some club members had spent a lot of time rebuilding the winch to use the large diameter Skylaunch drums, and made a full cab, etc. After failures with the club's other winch, it was decided that this winch needed to be finished ASAP - hence was sent to Skylaunch for them to finish the work in Autumn 2019. It was received back at Rivar Hill and commissioned in January 2020.

Work Done By Skylaunch - Aug-Dec 2019

• Made new engine & transmission mounts to correctly install club-supplied Chevy 454 engine & TH400 short tailshaft transmission.
• Fabricate and powdercoated a second cable drum. Supplied a second roller box and fabricated mounts for this
• Finished fabricating drum covers and fabricated additional guards, cables guides, substantial mudguards, etc
• Added window frames to the cab structure, added steel sheeting, door latches, battery mounts, vent windows, glazed the cab, etc.
• Created drum-stop system to prevent cable run-off when each side's drum is engaged.
• Installed their Throttle Stop Control Panel system with hydraulic brake levers, etc.
• Installed club-supplied starter motor, supplied Alternator, wired this all in to the engine, etc.
• Fitted new HT lead set, new Distributor Cap (large HEI type), Rotor Arm.
• Had the propshaft rebuilt. Supplied and modified to fit Skylaunch style exhaust manifold/silencer systems.
• Water radiator was modified and pressure tested. Mechanical fan added to front of engine, replacement short Chevy water pump installed, electric fan added to front of radiator. Thermostatic switch added into top hose. 180 deg F high-flow thermostat fitted to engine.
• Fitted used but good condition oil cooler and fan assembly and new hoses.
• Engineered new single lever system to operate the cable guillotines.
• Supplied & installed used but good condition 425 gas carburettor, Impco evaporator and solenoid.
• etc, etc...
  • It was agreed that to keep costs down, the club would organise things like fitting the radio and aerials, and painting things like the mudguards, wire mesh guarding, etc.

Safety Interlocks

• Safety lock on the guillotine lever. This is to stop the guillotines being fired accidentally, or as the winch is moved around the airfield. Ensure the lock lever is slid out of the way before the day's launches commence.
• There's a microswitch fitted to the transmission drive engage lever - this is to stop the winch from being started with the transmission in gear. If the drive lever is in "Drive" it prevents electrical current getting to the starter motor.
• Due to an incident in Summer 2019, the Committee decided to ask Skylaunch to fit an interlock set of switches on the drum engage levers - this further stops the winch from being started with either cable drum engaged.
• There's a mechanical interlock which prevents both cable drums being engaged at the same time.
• There's a warning buzzer which comes on IF a microswitch senses that the brake lever is "ON" AND the Drive lever is engaged. If this buzzer sounds when the drive lever is engaged, just check a) the brake weight has been removed, and b) if so, just push gently forward on the brake lever. this should stop the buzzer sounding. This needs some gentle adjustment of the microswitch position.
• Finally, there's a "low charging voltage" warning buzzer - if the engine is running and the voltage falls below a set amount this buzzer goes off. If this happens, just raise the revs of the engine a little with the throttle lever. This usually stops the buzzer, even when the revs reduce to idle.

Specifications

• Engine Chevy 454 Big block - see separate page for details
• Fanbelt Spec: XPA 1250
• Engine coolant: Uses the Red coolant - has better anti-corrosion properties than the old blue type. Do not mix blue and red coolants!
• Engine Oil Filter: FRAM PH5 ( See here for others: https://www.oilfilter-crossreference.com/convert/Fram/PH5 )

• LPG tank: A new tank and fittings was installed in 2012. The same make and type as fitted to the Skylaunch, obtained from a very helpful company called TinleyTech https://tinleytech.co.uk/ +44 (0)1767 676181. The tank used is a 4-hole Cylinder Tank 360x892mm 80 litre capacity. Remote ACME-JIC filler.

• Transmission: Chevy bellhousing, short (4") tailshaft. Purchased by club from Skylaunch in April 2019 for use in the Skybrid/ X winch. Was used in that from April 2019 to August 2019.

• Blue Powdercoat / paint: RAL5002 (Ultramarine Blue)
• Yellow Powdercoat / paint: RAL1003 (Signal Yellow)

• 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. 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. 205R16 tyres. These rims are readily available secondhand or new.

Spares

• New starter motor in cardboard box in red container (note - this is specific to the Chevy, will not fit the Oldsmobile, or vice versa)

Work Done (reverse chronological order)

• Microswitch that senses position of Drive/Neutral Lever found to not be working. Skylaunch supplied new switch FOC. JH fitted it - note: If ever replaced again, do not overtighten - the bolts can crush the switch. Just tighten the bolts enough to stop the switch form moving. Also, monthly guillotine checks done - 24th July 2020.

• March to May 2020: Martin S installed a radio mount and aerial into the winch cab. Also, a guide tube and cast weight and pulley system was installed - to improve the tow-out braking system. A team of volunteers also painted the mudguards.

• New alternator fitted - on site by Skylaunch.

• 7th January 2020: 2 full new cables installed.

• 6th January 2020: Club battery installed, insulation added to battery clamp bar. Control panel voltage meter mounted & wired in.

• 4th January 2020: Skylaunch delivered Rebuilt Winch to Rivar Hill. Test launches done on old cable on one drum that club had supplied.

• Late December 2019: Skylaunch adjusted and test fired the guillotine system. New oil filter and engine oil changed.