Warn 5687

So I picked up a Warn 5687 (Belleview) winch, last week for $50. I figured I really couldn't beat that price considering most parts are available through Herm and other sources. It came with the "knife" switch style relay but no controls. Once I got it home I tested the motor and everything seems to work just fine. Obviously no power out on these winches, at least in stock form. So I did some cleaning and changed the oil in the case and worked on mounting it to my bumper.



I ended up purchasing 4 ATV winch mounts from Harbor Freight and welding them back to back. Then I cut and notched the bumper where the winch was going to sit. The bumper had already been cut to fit a fairlead for another winch so I used that to initially mock everything up.


Here is what I came up with, I still need to get control cables which I've found at Napa I am also planning to go with synthetic rope. I'm contemplating boxing the bumper or adding gussets to the frame to help with strength, luckily my front frame horns are already boxed in.

 

You will likely want to change the fairlead rollers for rope. Daystar makes a direct fit set. I made my own out of Delrin that left only about 0.030" clearance between the rollers at the corners to hopefully keep the rope from getting pinched. Nice job.

 

Steel rollers work fine with rope as long as they haven't been damaged from prior cable use and the corner gap between the vertical and horizontal rollers isn't too big. You may also need to smooth out any marks on the old winch drum caused by the cable as it can snag the new rope.

Mike

 

Looks good, another vintage winch brought back from the brink...
I used a heavy solenoid and a momentary switch (push button) instead of my knife switch. The winch will hold 150' of cable or ? of synthetic line

 

I'm not sure how much rope it will hold. I ordered 100' of 3/8 and that seems to fill the drum pretty well.

 

They will hold 150'

 

They came with 150' of 5/16"cable. Post up a pic of the loaded up spool. What brand rope did you buy. I have 150' of cable on mine.

 

These old Warns will easily take 130-150 feet of 3/8" synthetic rope once you get the rope stretched. When I was selling this stuff, I was a dealer for ASR Offroad brand ropes. They are very good quality, made in the USA, and you can get custom coloring. My go to was a safety orange rope with the first 15-20 feet of the drum end colored yellow. This gives a great visual indicator to stop unwinding before you go to far.

Also, I never used any of the mechanical fasteners to attach the rope to the winch drum. A couple of strips of duct tape would hold a tag end along the length of the drum, then start winding wraps over the tag end. By the time you had two wraps on, you couldn't pull it off by hand. By the time you had 6-8 on, it wasn't going to move under a load either.

Mike

 

Sorry I don't have any pics of it spooled. But this is the rope I purchased https://www.amazon.com/gp/product/B07VK41DG6/ref=ppx_yo_dt_b_asin_title_o02_s00?ie=UTF8&psc=1
It appears to be good quality and there is a 1 year warranty on their product.