Magnum 9k winch - troubleshooting connection

[Discofever]

I need some guidance. I've purchased a new winch that I have installed on my Disco, trouble is the Magnum 9k winch I removed needs a new steel cable. I purchased one and removed the old cable but noticed that the end of the cable was not attached to anything (i.e. not attached to the drum) it was just wound around the drum. I purchased the winch second hand so did not fit the old cable but I am unnerved that the end of the cable wasn't attached to anything.

The end of the new winch cable I have purchased has a small hole in the end on what appears to be a soft metal flat crimp. There is a nipple on the inside of the drum but the hole at the end of the cable will not fit over this nipple - I would have to enlarge the hole to fit.

My question is does anyone worry about attaching the start of the steel cable to the drum or do you just rely on having enough cable around the drum (i.e. 6-8 times around) to keep the cable taut and on the drum? To be honest with you the metal at the start of the new winch cable is soft and does not appear that it would make much difference than just winding the cable around the drum. Anyone have a magnum winch or advice on how you connect the start of the cable to the drum? This is obviously a safety issue and I would like to wind the new cable on and sell the winch but I'm not selling it to someone if there are issues with the attachment.

Thanks in advance. John.

[Loubrey]

Hi Mate,

The two connections in use is basically an eyelet crimped to the rope (metal or synthetic) which is bolted to the side flange of the drum (used on Warns) and the tapered hole on the drum spindle type which is held in place by a grub screw (This method is used quite seldom). Neither method serves any bigger purpose other than helping you spool the line on the drum.

As you correctly mentioned, the wrapped rope on the drum is the actual connection and the basis for the associated strength.

So answering your question, drilling the crimped hole a bit bigger will make no difference and certainly won't make it unsafe to use.

The intriguing question is the nature of the "nipple" you are describing... Is it actually like a grease nipple screwed into the flange (possibly using the actual connection hole)? If so, it would actually be prudent to just replace it with a domed allan head bolt in the right size as per original (M5 x 10mm if I remember correctly) which will most probably mean the hole in the crimp is the correct size to begin with.

Cheers,

Lou

[Discofever]

Hi Mate,

The two connections in use is basically an eyelet crimped to the rope (metal or synthetic) which is bolted to the side flange of the drum (used on Warns) and the tapered hole on the drum spindle type which is held in place by a grub screw (This method is used quite seldom). Neither method serves any bigger purpose other than helping you spool the line on the drum.

As you correctly mentioned, the wrapped rope on the drum is the actual connection and the basis for the associated strength.

So answering your question, drilling the crimped hole a bit bigger will make no difference and certainly won't make it unsafe to use.

The intriguing question is the nature of the "nipple" you are describing... Is it actually like a grease nipple screwed into the flange (possibly using the actual connection hole)? If so, it would actually be prudent to just replace it with a domed allan head bolt in the right size as per original (M5 x 10mm if I remember correctly) which will most probably mean the hole in the crimp is the correct size to begin with.

Cheers,

Lou

Excellent - you explained everything I needed to know. Thanks.