Winch Connector repair

[MP&C]

No really.... welding and hammer forming!!


Found a shelf casualty on the new winch we bought for the car trailer, appears the box was dropped at some point or this controller connector is just garbage.

Being a Sunday with little open to fix this, lets see what we can do.. Measurements....

Trying out some plastic fusion welding using a soldering iron... we better hide that...

Used socket as a dowel pin, hammer form plates cut out of 10 gauge steel scraps.. Our cover will be made out of polished stainless for resistance to the elements. The stainless piece is cut about 1/8 larger all around (1/4" total) so we have enough for a side lip..

Just resting here for the picture, but one "tab" was clamped in the vise, vise grips clamped the open side, and the flange hammered over. Pulled out, rotate, repeat. About 5 minutes later and we are done.

Installed...

That should hold us..



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['68 Coronet R/T]

Your creativity is amazing. I would have been living with the glued together mess.

 

[Machspeed]

Very nice! Despite answering my plethora of questions, you were able to do that....lol!

 

[jlcustomz]

I've done lots of similar repairs making a plate from easier to bend aluminum. Fusion welding is the strongest repair for plastic, but they lose strength due to not having same molecular structure unless you make thicker with donor material. Or make a cool ass reinforcement cover that looks like it's meant to be there..
Nice work, but why does everything have to be made so brittle & require us fixing everything all the time. Funny how many things I have that have been repaired for longer than they were new unbroken. Guess that's what makes doing repairs worthwhile. Sometimes if you just get a new part, it will just break again.