Bit out of my element here, and there is such a huge variety of expertise on Sigforum, I thought I'd toss this oddball question out there and see if I can get some advice.

Purchased a new/used winch for the Jeep. NIB, but from a private party, so no warranty. It didn't work. I took the risk buying it used to save a few bucks, so I understand what I did. I'll buy a new one if all else fails.

Took me a bit of troubleshooting to ID the problem, but it looks like one of the leads to the magnets (I think that is what it is called) inside the motor isn't fully connected. Manufacturing defect, but it isn't covered since I didn't buy it new.

Picture below is the case of the motor. The armature has been removed. Lead on the left isn't connected to the post through the case (you can slide a putty knife between the lead and post). Lead on the right works fine. Post on the case is where the winch hooks up.

How do I know this? 1) Hook up power/grounds to the leads. One on the right gets power to the wire, one on the left does not. 2) Did a quick (not very good) solder job to the lead on the left and voila, winch worked.

Took it back apart to clean up and connect the lead the proper way. Not sure what the proper way is.

I'm not sure if solder or expoxy is the right tool to use to put it back together. Obviously, it would be some sort of electrically conductive epoxy.

Concern with solder is the coating on the wire/post prevention good solder connection (basically, what I put on before just chipped off). Might not allow a good connection, especially under the wire. Long term reliability. Heat from the motor.

Concerns with electrically conductive expoxy are similar. Possibility of a not good connection, never used it, expense.

Of course, I could be way off base on the proper repair technique.

I'm guessing on the part names, so I don't even know what to call them for a proper Google search. I understand the basics of how all this stuff works, just not sure on the details about attaching the parts. A new motor is over $200, so at that point, I'll just buy a new winch ($400).

Thanks for the help and advise!

Epoxy is not the answer and soldering is probably not a great choice either. It's melting point is pretty low and could go liquid under heavy use.

The correct or factory method used on copper to copper connections like that is a spot weld. It looks like they screwed that up in manufacturing.

If it were me, I'd remove the post and tap is for some (3) small machine screws, drill matching holes in the flattened conductor and fasten it that way with short screws. You might just tap one larger hole at the center of the stud as well.

Look up an electric motor winding shop. There are several in Dayton and take it to them.

quote:

Originally posted by kg5388:
Look up an electric motor winding shop. There are several in Dayton and take it to them.

An automotive electric shop that rebuilds starters and alternators would be another place to try.

Winches can pull a LOT of current, so I don't think either of your solutions will really work. You probably need either a weld or some kind of clamping solution. I would echo the other comments and ask at a shop that rebuilds alternators or other electric motors.

I noticed you’re in Dayton. Take it by M&R motor and have them take a look at it. Don’t try to repair it yourself.

FYI
That would usually be called a stator winding. Was probably done at the factory with an electro-brazing machine and hi temp silver solder, then coated with insulating varnish.
Motor shop should be able to help.
If not, motor maker may sell just the windings with the studs attached for less that a complete unit. Never hurts to ask them to help you out with what looks like a bad factory (cold) solder joint.
Be careful and support the stud when tightening the cables. Possibly that is what happened before you got it.

As everyone already knows, this place is great. The wealth of info on here is mind boggling.

I'll be the first to admit, I do overthink things. It crossed my mind to take it somewhere, but not to get it welded.

Dropped it off at M&R Motor (they were fantastic to deal with) on the way to Costco, picked it up on the way home. A few bucks out of pocket and now have a functioning winch!

Thanks Sigforum!