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View Full Version : Incab winch control +++ wireless & wired remotes & key switch with lockout



Hunty
11-10-10, 09:57 PM
Hi Guyz
I woke up sunday morning and all was well, Bathurst 1000 on the TV, a perfect day brewing until - I had a great idea - why not install a switch inside my Jeep to run my winch!

So I took a fistful of smarta$$ pills and begun!

I decided I wanted to keep the original SmittyX wired remote and add a wireless transmitter / receiver and a switch inside the cab near the steering wheel.
After much sitting around and watching the great race I realised that I really should install some kind of hidden switch to disable the winch so when I park it with the roof off people will not be able to reach into my cab press the winch out button and easily rip off my dyneema rope (which I keep tightly spooled onto the winch - so tight in fact that the mechanical free spool release can't be operated until some slack is created by pressing the winch out button for a few seconds.

I grabbed another handful of smarta$$ pills and realised immediately that if someone with a smittyX wired remote control really wanted my dyneema rope they could just plug their winch control into my winch and spool it all out - so I needed a master lockout switch preferably in the cab and preferably with a key

finally I got motivated to do it and thought what if someone sitting inside the cab (baby sitting the steering wheel and brakes) were to press the winch out button whilst I was outside the cab overseeing the winching and pressing the winch in button on the smittyX remote or the wirelss transmitter "would the winch blow up in spectacular fashion??? (If you know what happens please post up) - a lockout of some sort needed to be engineered!

quick tally up
1. Wired remote
2. Wireless remote
3. Incab switch
4. Master lock with key switch
5. electrical lockout system

I went to the wreckers because I knew that car window switches have a lockout system built in to stop dad in the front and little johnny in the back both pressing opposites (up & down simultaneously) and blowing up the window winder

I wanted a slimline switch - i had seen other JK Jeeps with Arb switches mounted in the A pillar and wanted to try to get a little more subtle installation so I found a nice (LoL) SSangyong Musso 4x4 at pick a part and extracted its rear window switch.

Holdens still leading so I got bored with the race and started to sketch possible circuit diagrams (as per pic lol) and realised that I would need at least 2 relays to ensure fool proof lockout

Final tally
1. Wired remote
2. Wireless remote
3. Incab switch
4. Master lock with key switch
5. electrical lockout system inc 2 x 12v relays with N/O N/C contacts
6. Hookup wire
7. Fuse holder and fuse
8. Convoluted plastic split tube to protect wire going from Cab to winch
9. 3 way selector switch - Jaycar i off ii
10. 2 more boxes of smarta$$ pills - because this became a real noodle scratcher

Step 1
cut in switches - i preffer to use a piece of cardboard and cut a hole with a stanley knife and test fit my switches in the cardboard first - when I get the perfect fit I trace the hole onto the A pillar and then cut with a sharp knife and file with a metal file to get the hole as perfect as I can!

Step 2
open the passenger door, remove the side dash pannel and you will see a hole blocked with yellow insulation material, get a big screw driver and poke through it - you now have acess from cab to engine bay - install cable

Step 3
wiring, soldering and crimping

Basic wiring concepts
1. the key interrupts the 12v coming from the winch controller b4 it gets to a) the in cab switch b) the wireless remote and c) the standard smittyX wired remote control

2. The little switch (i off ii) is connected to both relays (i) to relay 1 and (ii) to relay 2 - 12v positive in ---- the negative in is connected to the Jeeps earth - when the switch (i) is pressed the relay (1) is activated the same goes for switch (ii) and relay 2 - --- because the relays provide a N/C output (N/C stands for normally closed - relay output is on even when the relay is not energised) it is possible to wire the incab switch through the relay N/C connection! ---- this will mean that when the switch is pressed (activating the wireless or wired remotes) and the relay is activated the in cab switch will get disconnected. (sorry if I am making no sense - run out of smarta$$ pills - LoL - if anyone can better explain this little relay magic please post up!

3. Connect everything up but keep the main 12v feed (350amp big red cable) to the winch off the battery incase of any D'oH fickle finger of fate actions - test with multi meter to ensure all works as desired.

in conclusion
The Key is the Master switch
the little switch determines which of the 3 input options will go to the winch
Wired remote, wireless remote and in cab switch
It all works well and looks neat and I don't have to worry about blowing up my winch

If anyone has any suggestions on how to improve the system please post up
enjoy
cheers Hunty]


http://i685.photobucket.com/albums/vv217/ashunty/Huntys%20Jeep%20JK/DSCN1055.jpg

http://i685.photobucket.com/albums/vv217/ashunty/Huntys%20Jeep%20JK/DSCN1056.jpg

http://i685.photobucket.com/albums/vv217/ashunty/Huntys%20Jeep%20JK/DSCN1057.jpg

Hunty
11-10-10, 10:00 PM
more pix - could'nt fit into first post
http://i685.photobucket.com/albums/vv217/ashunty/Huntys%20Jeep%20JK/DSCN1046.jpg

http://i685.photobucket.com/albums/vv217/ashunty/Huntys%20Jeep%20JK/DSCN1048.jpg

http://i685.photobucket.com/albums/vv217/ashunty/Huntys%20Jeep%20JK/DSCN1052.jpg

Steve F
11-10-10, 10:15 PM
Very nice work.

Cheers
Steve

TRBN8R
12-10-10, 05:21 PM
U r one crazy inventor mate.

Great work........

Wolfe
13-10-10, 12:38 AM
I'm too lazy I just got one of these http://www.4wdandsportutility.com/newproducts/0412_4wd_roadless_gear_dash_mounted_winch_control_ product_review/index.html



http://image.4wdandsportutility.com/f/9936804+w750+st0/0412_4wd_01_z+roadless_gear_dash_mounted_winch_con trol.jpg

Wolfe
13-10-10, 12:46 AM
heres an install http://www.expeditionportal.com/forum/showthread.php?t=16563

Hunty
13-10-10, 03:53 PM
Hi Maaaate
It looks good, functional and sits very tidy on your dash - I looked at roadless gear but soon realised that I wanted to make sure only 1 of my 3 inputs (Wireless,wired and incab) could control the winch at once - not sure what would happen if in & out solenoids were to get pressed simultaneously .
Do you run dual batteries??? and if so what kind r u using and with which controller
cheers Hunty



I'm too lazy I just got one of these http://www.4wdandsportutility.com/newproducts/0412_4wd_roadless_gear_dash_mounted_winch_control_ product_review/index.html



http://image.4wdandsportutility.com/f/9936804+w750+st0/0412_4wd_01_z+roadless_gear_dash_mounted_winch_con trol.jpg

Wolfe
13-10-10, 08:02 PM
Nah thats not my dash, mines stil in the box got to work out where to put it yet :)
I've got lots of plans to do dual batteries and air tank etc just no time

Hunty
13-10-10, 08:12 PM
OK LoL
if you need a hand to get it in and sorted I would be happy to help
cheers
Hunty

Wolfe
13-10-10, 09:06 PM
Thanks mate I might take you up on that

TK421
26-10-10, 12:43 PM
Hunty - from now on, you shall be known as Albert! Must have been the fact that you drew your master plan at ten minutes past ten in the morning.