Rob 12B1P

I changed out the roller fairlead for a smooth aluminum one. My drum had no burrs but If there were I would have just touched it up with some sandpaper/paint. I got the Smittybilt 10k rope and it came with a sleeve on the first several feet to protect the rope from the drum. From my research for my winch I have to limit running out the rope under power as the winch is working against the brake and generates a lot of heat which could damage the rope. Better to freespool out when possible. Im guessing your winch probably has a similar braking system but you might want to research it.

Rogue26

What are thoughts on over current protection from the wiring feeding he winch? All of the winches on my companies work trucks have either a fuse or circuit breaker on them but most of the personal winches I have seen have nothing. Realize the size of the over current device could get big. I am just starting to look at winches and am trying to learn the basics.

GJeep

I have the Warn Zeon 10-S. It has a thermal protection.
I added no fuse or circuit breaker.

Read this for replies to your question --

Winch wiring: Need Circuit Breaker advice - Jeep Wrangler Forum

Warn offers an accessory 'Power Interrupt Kit' PN 62132 --This can be easily made form a solenoid, wires and a switch.

A simple disconnect switch for high Amp., for when the winch isn't used, is another option.

Owl

I went with a high-current switch, at the battery. It's "off" normally, and has to be switched to "on" when I need the winch. Kind of a pain, but better than nothing. The issue is the wire / conductors to the winch, which could overheat due to excessive current, and possibly cause the insulation and surrounding flammable materials to ignite. The Warn option that GJeep references (a high current solenoid and remote switch) is very ingenious, and would serve very well. There are high current DC circuit breakers available (and fuses), but selecting the correct size / amperage of overcurrent protection would be tricky (depending on the full load current used by the winch motor).

GJeep

In addition --

I think that real thick +/- cables to the winch, wired so each touches nothing on the way, would give 99% peace of mind.

Rogue26

Might just be the electrician in me but I was alway taught that you have OCP as close to the source as possible with your wire sized to it. Nice that the winches have built in protection to protect themselves and if you could keep the wire isolated in case of a short then all would be well but how realistic is it to run from the battery out to a bumper mounted winch with out the conductor touching anything that ties to the negative? I am still a little ways off from buying mine since the wife has squashed most of my jeep spending until after the new year but I appreciate the feedback.

GJeep

A thermal/abrasion protective sleeve on the cable can give you peace of mind.

Example --

Owl

Yep, overcurrent protection as close to the battery as possible. Hence my choice to place a switch there (as the OCP calculations required a very large fuse [just wouldn't fit]).

WINGIT

Most you can't swap. If the brake is in the drum it gets too hot for rope.

I have the syn X2O and love it.

adamisadam

Great site, thanks. This has been a problem with old Pontiac starter wires for years. They originally ran positive wire from battery all the way to the starter, usually snaking it along and next to the engine and exhaust manifold! This was the cause of many fires.

One solution was to get a Ford starter relay similar to the setup sold by Warn, except the Ford relays are around $25. Search the net on the subject, tons of info.This relay could be applied to the winch too.

Mine has been on for about 6 years. I need to inspect the wires and consider looms for protection. Not sure I'd bother with the relay at this point, but it is worth considering.