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Winch Disconnect Switch and Mounting Plate #5317000 01/08/20 05:37 PM
Joined: Sep 2010
Posts: 8,230
2015_PSD Online Content OP
OP Online Content
Joined: Sep 2010
Posts: 8,230
I waffled quite a bit on using a 500amp solenoid or a disconnect switch for the power to the winch. I did not want constant power to the winch and wanted a way to break the connection. I elected to install a disconnect switch so that I do not lose one of my auxiliary switches to power the solenoid and a solenoid would likely be one more thing to fail when it is needed most.

I am still in the mock up stages, but I thought that I would share what I have done so far. I made a template out of cardboard and traced it out onto a 1/4" thick T6061 aluminum plate grabbed from Amazon to mount a Blue Sea Systems disconnect switch also from Amazon.

Enjoy!

Raw Plate:
[Linked Image from iili.io]

Finished Plate:
[Linked Image from iili.io]

Mock of Plate 1:
[Linked Image from iili.io]

Mock of Plate 2:
[Linked Image from iili.io]

Switch View 1:
[Linked Image from iili.io]

Switch View 2:
[Linked Image from iili.io]

Switch View 3:
[Linked Image from iili.io]


2019 o)|||||(o Rubicon Wrangler Unlimited 3.6L V6 [Castrol Edge + Mahle]
2018 Mercedes Benz C300 2.0L Turbo [Pennzoil Platinum + Mann filter]
Re: Winch Disconnect Switch and Mounting Plate [Re: 2015_PSD] #5317252 01/08/20 10:01 PM
Joined: Mar 2012
Posts: 1,690
E
E150GT Offline
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E
Joined: Mar 2012
Posts: 1,690
Very cool. I like projects like this.


1984 Mercedes-Benz 300SD - 100k
1995 F150 XL 4.9 reg cab 5MT - 251k 5w30
2016 Mazda6 Touring 6MT - 68k 5w30
2006 Buick Lucerne CXL 3.8 40k 5w30
Re: Winch Disconnect Switch and Mounting Plate [Re: 2015_PSD] #5320959 01/12/20 05:27 PM
Joined: Sep 2010
Posts: 8,230
2015_PSD Online Content OP
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Joined: Sep 2010
Posts: 8,230
All finished (just some minor cleanup remaining). Now I simply turn the switch on before heading off road and back off again when back in civilization.

[Linked Image from iili.io]


2019 o)|||||(o Rubicon Wrangler Unlimited 3.6L V6 [Castrol Edge + Mahle]
2018 Mercedes Benz C300 2.0L Turbo [Pennzoil Platinum + Mann filter]
Re: Winch Disconnect Switch and Mounting Plate [Re: 2015_PSD] #5320969 01/12/20 05:35 PM
Joined: Sep 2010
Posts: 11,415
4WD Offline
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Yeah ~ I used to make sure they are out of the line of fire if the cable breaks … looks like you have done that.
I’d also recommend safety glasses and sturdy impact style gloves.

Re: Winch Disconnect Switch and Mounting Plate [Re: 4WD] #5320997 01/12/20 06:25 PM
Joined: Sep 2010
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Originally Posted by 4WD
Yeah ~ I used to make sure they are out of the line of fire if the cable breaks … looks like you have done that.
I’d also recommend safety glasses and sturdy impact style gloves.

The controller is wireless and the cable is synthetic so less energy released if it snaps and I use snatch blocks and cable dampeners too (can never be too careful).


2019 o)|||||(o Rubicon Wrangler Unlimited 3.6L V6 [Castrol Edge + Mahle]
2018 Mercedes Benz C300 2.0L Turbo [Pennzoil Platinum + Mann filter]
Re: Winch Disconnect Switch and Mounting Plate [Re: 2015_PSD] #5321003 01/12/20 06:29 PM
Joined: Sep 2010
Posts: 11,415
4WD Offline
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Posts: 11,415
Saw that non metallic when my wife forced me to look at Wranglers 😜
Is that made from Spectra ?

Re: Winch Disconnect Switch and Mounting Plate [Re: 4WD] #5321274 01/13/20 06:31 AM
Joined: Sep 2010
Posts: 8,230
2015_PSD Online Content OP
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Originally Posted by 4WD
Saw that non metallic when my wife forced me to look at Wranglers 😜
Is that made from Spectra ?

It is a Smittybilt 12K winch that came with synthetic rope, I am not sure who makes it for them.


2019 o)|||||(o Rubicon Wrangler Unlimited 3.6L V6 [Castrol Edge + Mahle]
2018 Mercedes Benz C300 2.0L Turbo [Pennzoil Platinum + Mann filter]
Re: Winch Disconnect Switch and Mounting Plate [Re: 2015_PSD] #5321284 01/13/20 06:53 AM
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Posts: 11,415
4WD Offline
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Ok … maybe Dyneema

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