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 In-Cab Winch Control for XRC8 « View previous topic :: View next topic » 
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AZLugz
PostPosted: Thu May 08, 2008 12:26 pm    Post subject: In-Cab Winch Control for XRC8 Reply with quote

Learner
Learner

Joined: 22 Oct 2007
Posts: 99
Location: Mesa, Arizona

[Install] In-Cab Winch Control for XRC8

This is a project I did on my Jeep but it really would be similar for most any project.

This is my homespun In-Cab Winch control setup for my Smittybilt XRC8 winch


I have seen this issue come up a lot and have been "Gonna do it" for a long time, well, I was at 4 Wheel Parts last Friday and was checking out Ethan's Sami buggy and his homemade in-cab and decided to do it but a little different.

The research and design had to come first and I found that the XRC8 is a 3 wire control with White as the hot lead, Green as the In lead and Black as the Out lead.....Can you get any better than that.....the same color code as common house wire. So, first stop was Home depot for wire and sure enough, no helpers and I am in a hurry, the spool of cheap stuff is empty so off to the extension cord isle......AhA, I nab a 25' 16/3 bright orange extension cord for $4.97, yes, a little more than the plain wire but quick. For those "not in the know", 16/3 means that this wire has 3 conductors that are all 16 gauge. Typically extension cords are also stranded copper wire and run standard internal color code of Black=hot, White=neutral and Green=ground......that mtters not in my case except that the colors match the project and make it easier and being an outside extension cord, the 3 wires are encased in a water and oil proof sheath. Makes running the wire easier and look better.

Next stop is Radio Shack for the electronics. I went a little extra because I wanted protection from accidental engagement and I wanted lights to verify direction and movement. Here is my rough schematic: (Disclaimer.......I worked in electronics for over 20years so I know the stuff BUT the schematic is so bad because I have NOT worked in MS Paint for 20 years!!)



So, I picked up an Arm/DisArm style Master switch so it could not be "bumped" on, a momentary push button, a 3-way (on-off-on) and 2 LED lights (red and green).

This install/build took place in the driveway at the RV park where my Parents are snowbirding here in Mesa, so it's definately not a hard job!!!

I started off with the solenoid cover and on the Smittybilt it is riveted on, so I had to drill out the rivets. Next was to fanagle the wire from the winch to the firewall and inside to the location for the controls. Take time on this job, make it look good but make it safe and secure. Use wire ties to keep the wire in place so it will not get caught on something or rub a hole.

Since the winch is always "hot", I wired the inside first....yes, I know, you should always disconnect the battery and I will say here that for safety, I suggest you do that even if I don't,. I decided to use the small square panel where the ashtray used to be on the jeeps but mine does not have. This picture already has the pushbutton in:



Next was the master switch:



Then the 3-way and 1st hole for the LED's:



I am not going top post the wire connection as I used push connectors as a temp setup and I intend to get a 12-pin connector for all the switchs on this panel and then solder all connections when I put the panel connector in. So, with all connections made inside but the panel still off in case troubleshooting is needed we head back to the winch.

Wiring is cut to length, half rings crimed on and screwed in:



I then secured the wire in place with tie straps (UV safe) and the reattached the cover using sheetmetal screws in place of the rivets. The wire coming out was also secured to the main winch wires with straps:





Back to the inside, we tested the setup and all works great so we reattached all the panels and completed the work. The finished dash.....sorry for the dirt but....1. its a jeep, 2. it was on the trails this weekend!!!!





With the system set up this way, the master switch has a red LED built in that comes on when it is engaged. The 3-way is flipped up for in and down for out. When you press the momentary button with the 3-way in the up position, the green LED will light while the winch will spool in, like wise, in the down position, pushing the momentary will cause the red LED to light while the winch to spool out. I intend to have some small stickers made to denote directions and functions but that I have to send out for them. We are going wheeling this weeked, maybe we will get to test it out!!! Must say thanks to my Dad and my son for helping along on this and other projects!!!!


Note: The small connector above the master switch is the IPOD input for the stereo.


Edit: For approimate costs:

Master switch... $4.99
3-Way.. $2.99
Mom Switch... $2.29
2 LED's ... $3.38
Ext Cord... $4.97
Straps... $1.79
Connectors... extras but say $1.29 for a pack

Brings it all in at just over $20 depending on the switchs and lights you choose, also, buying the wire off the spool in the lengthyou need will save a little.


Last edited by AZLugz on Mon May 12, 2008 4:15 pm; edited 1 time in total
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DASwin
PostPosted: Thu May 08, 2008 12:37 pm    Post subject: Reply with quote

I Helped!
I Helped!

Joined: 05 May 2008
Posts: 14
Location: Rochester MN

Love the write-up! The project looks great and appears easy to duplicate. I don't have a winch yet but would like to do an in-cab system like this one. Keep us updated on how it handles the trail abuse. One other option for the less savy person would be this site
Roadless gear More money and less respect from other jeepers but another option
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DailyDrivenTJ.com
PostPosted: Sun May 11, 2008 5:42 pm    Post subject: Reply with quote

Site Founder
Site Founder

Joined: 09 Apr 2006
Posts: 1768

Thanks for the write up! I will get featured in the front of the website on the next update!

I like how you setup the momentary switch for the motor with the mode selector. Great job!

Every once in awhile the 400ft wire spool in various gauges are sold around $20. I picked up mine and I don't think I will run out of wires for awhile for electrical projects.

http://www.harborfreight.com/c.....umber=3384


HTH,

Michael
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06trailrig
PostPosted: Sun May 11, 2008 11:53 pm    Post subject: Reply with quote

Newbie
Newbie

Joined: 21 Apr 2008
Posts: 43
Location: Calhoun, GA

great writeup tu i'm going to get the XRC8 next week so I appreciate this piece of info. I'll be doing this as soon as I get the winch.
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cpleasant
PostPosted: Fri Jun 20, 2008 6:04 pm    Post subject: Reply with quote

Newbie
Newbie

Joined: 20 Jun 2008
Posts: 2

HEre is a question for you. Im looking to install similar in-cab controls. However, I was thinking about adding back up relays in the cab controls rather than splicing into the winch's controls so I have a back up.

My idea was to run the interior switches to a relay which will hook directly to the winch's power leads, just like the original solenoid. That way either the winch's solenoid or the original remote control operated one can work the winch. Anyone see a problem wiht that?


The only thing that was brought up was the possibility of a short with no protection circut. On the winch's schematic, I dont see any type of protection circuit to begin with. Does anyone know if the solenoid includes some kind of internal circut breaker-type feature that isolate the winch from the battery in case of a short? I know wire going to the battery itself has no sort of protection, I was just wondering if there was any at all?
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RblPrd
PostPosted: Sat Jun 21, 2008 10:16 pm    Post subject: Re: In-Cab Winch Control for XRC8 Reply with quote

I Helped!
I Helped!

Joined: 15 Mar 2008
Posts: 29
Location: Arlington, TX

AZLugz wrote:
[Install] In-Cab Winch Control for XRC8



I cheated, well not really, won an in cab winch controller from 12voltguy.com

same concept thou, for the lazier of us HI HI
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DailyDrivenTJ.com
PostPosted: Sun Jun 22, 2008 12:27 pm    Post subject: Reply with quote

Site Founder
Site Founder

Joined: 09 Apr 2006
Posts: 1768

cpleasant wrote:
..lenoid or the original remote control operated one can work the winch. Anyone see a problem wiht that?..


Surely doable, but I am sure those solenoidS that pull hundreds of amperages through the battery will not be cheap. If you are thinking about hardwiring the motor to the a switch then, you are risking your physical well being. :)
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cpleasant
PostPosted: Mon Jun 23, 2008 1:56 am    Post subject: Reply with quote

Newbie
Newbie

Joined: 20 Jun 2008
Posts: 2

How many amps does a starter pull vs a winch? I was thinking about using an old starter solenoid from a 60-70's era vehicle, which are under $15 a piece. I could use one each (or two in parallel to split the current between them) for in and out. Hell, I could even call the manufacturer and get a solenoid from them. Just wanted to ensure I wasnt bypassing any internal saftey features in the original solenoid. I dont have an internal schematic for it.

And no, I had no plans to run a 20 amp Contura switch to something that pulls 10 to 20 times that amperage. loco
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DailyDrivenTJ.com
PostPosted: Mon Jun 23, 2008 6:00 am    Post subject: Reply with quote

Site Founder
Site Founder

Joined: 09 Apr 2006
Posts: 1768

Judging from my clutch job experience, starter will not draw as much as the winch motor because it doesn't take much to turn the flywheel.

Like I said earlier, it is SURELY doable, but unless you are going on an arctic exploration or an African safari on your own, having a back up on a winch to me seems overly excessive IMO.

Keep in mind, AZlug spent about $20 for his setup and it serves as the in-cab remote control purpose.

I know what you are trying to do is different but if you are really concerned about winch solenoid failing on you, then you can always "McGyver" the motor straight to the battery to power it up. Just gotta be careful and keep yourself out of the harms way.
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srlbotanical
PostPosted: Sat Jun 20, 2009 7:55 am    Post subject: XRC8 has been updated... Reply with quote

Newbie
Newbie

Joined: 10 Jun 2009
Posts: 1
Location: Saranac, MI

This winch continues to improve. Smittybuilt now has screws to access the cover, so no drilling out the rivets. They have also updated the Solenoid.

With this new winch version, if you attach the wires directly to the Solenoid posts as in the write-up, you will melt your in-cab wiring. You need to now tap into the remote plug wires BEFORE they enter the solenoid. I did this by cutting the three wires and reattaching them with a butt connector and an extra pig tail. I then used insulated connectors to tap into the pigtails. This all needs to happen Before the solenoid.

Steve
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