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Glynparry25

Member Since: 16 Feb 2009
Location: Miserable Midlands
Posts: 3015

2009 Defender 110 Puma 2.4 XS DCPU Tonga Green

My 8274 refurb

Good evening gents,

A few months ago I had 2 options with reference to the winch and bumper on my Defender. Either:

Superwinch Husky mounted in a MANTEC bumper,
or
WARN 8274 mounted in a TJM Roo bar.

Not an easy decision, Reliability . v . Performance. So I thought... "What if I could have both?". Besides, I was itching for a new project. So I took my £500 8274 which has had a relative easy life but unfortunately (as I found out whilst stripping) had a neglected life.

START:

Click image to enlarge

Click image to enlarge

-> As you can see, there is caked on mud which had cut into the paint surface and also destroyed the machined surfaces.
->All the grease used was of low quality and had turned into a rusty powder and was about as much use as a chocolate teapot!!
->The brake pads weren't greased and had seized onto the covers. The ball bearings were soo rusty they were were more like mini Ferero-Roche.
-> The motor was 80% motor and 20% dried clay

I started to think maybe I shouldn't bother, but I was going to change the motor anyway for a Bow2, and there were a few good points:

-> All the running gear was in great condition and no cracks or knocks to the aluminum housing

.
-> The electrics are all intact and even though caked in clay, it all worked

.

First off I stripped it sown to bare housing, had it sand blasted and powder coated in gloss black- this all cost £40 and the workmanship is as you would expect from German Engineering- it is a work of art.

On re assembly I decided to do a few little 'mods' to improve its reliability:

-> Gigglepin Top housing bush kit- This gets rid of the dodgy really fine roller bearings which were on their way out.
-> Gigglepin Brake pads and hardware kit- this was to replace all the corroded parts and the brake pads were used to improve the braking. As advised by top challengers, I have greases it all up with a top grade CV grease. All finished off with a aircraft grade cir-clip at the end so it doesn't go 'ping'- I may finish off and do a Gwyn Lewis mod to the end of it if I have any problems whilst testing.
-> All new bushes, gaskets and seals.... Why go to all this hassle and have a leak because I re-used a £5 seal!!
-> D44 end plate cover.

It is all coming together nicely..... Pics so far:

Click image to enlarge

Click image to enlarge

Other items to be fitted:

Bow motor 2.
Gigglepin free spool handle (in the post).
125' Synthetic rope.
WARN Fairlead.
LOCKING NUTS!!!!!!!!!

I will update as parts arrive and as I fix it up

. I still have the fun of cutting the grill and moving the A/C radiator fan.

Glyn

Anyone wet over the winch porn?

Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated

23rd May 2011 8:52pm

johnszs

Member Since: 16 Aug 2010
Location: Hereford
Posts: 459

2004 Defender 90 Td5 XS CSW Alveston Red

that will be a very nice bit of kit when its complete, i hope you dont just have it for show

how come the change?? 2004 TD5 Defender 90 xs station wagon

Last edited by johnszs on 23rd May 2011 9:03pm. Edited 1 time in total

23rd May 2011 8:56pm

fekete

Member Since: 24 Dec 2008
Location: Here on the other end of the computer
Posts: 3626

2007 Defender 90 Puma 2.4 HT Bonatti Grey

Nice job Glyn, and good write up

NEVER TAKE LIFE SERIOUSLY. NOBODY GETS OUT ALIVE ANYWAY

23rd May 2011 9:00pm

Glynparry25

Member Since: 16 Feb 2009
Location: Miserable Midlands
Posts: 3015

johnszs wrote:
that will be a very nice bit of kit when its complete, i hope you dont just have itr for show

how come the change??

The husky was awesome- I did love it, but with moving to Cyprus, I wanted the better frontal protection of the Roo-bars (and to mount aux lights), and I guess I wanted more performance. The challenge of building a good winch on a tight budget was an attraction too

I can't wait to test it out- I am sure there will be more than a million chances to when I am in Cyprus

.

Glyn

23rd May 2011 9:04pm

johnszs

Member Since: 16 Aug 2010
Location: Hereford
Posts: 459

where did you get the bumper from? are the lightforce lamps the 240's? 2004 TD5 Defender 90 xs station wagon

23rd May 2011 9:09pm

Glynparry25

Member Since: 16 Feb 2009
Location: Miserable Midlands
Posts: 3015

I got the bumper from Peter " Nakatanenga- He had it sitting on a shelf in his warehouse for ages so was willing to sell it to me.

The lights are Lightforce 240 XGTs- the Blitz wouldn't fit because they would sit too high and protrude way past the front of the bars

, but the light is awesome

.

Glyn

23rd May 2011 9:15pm

XS Pete

Member Since: 13 Jan 2011
Location: Suffolk
Posts: 632

2011 Defender 90 Puma 2.4 XS CSW Stornoway Grey

Glyn,

Just a minor word of caution. Be prepared for the Cypriot Police! They seem to have very inconsistent behaviour when it comes to nudge bars and extra lights. In some parts of the island (particularly in the West around Paphos) they periodically stop vehicles and give out spot fines to drivers of vehicles with aftermarket bars and spots fitted. There seems to be some unwritten law about only allowing these things on vehicles if they were factory fitted.

As I say, there seems to be no hard and fast rules about it, you might get stopped, you may not. I've never been stopped, but I know people who have.

Pete

23rd May 2011 9:23pm

johnszs

Member Since: 16 Aug 2010
Location: Hereford
Posts: 459

thanks for the info

well i know what i will be eying up once i am back from the isle of man tt

2004 TD5 Defender 90 xs station wagon

23rd May 2011 9:23pm

Glynparry25

Member Since: 16 Feb 2009
Location: Miserable Midlands
Posts: 3015

XS Pete wrote:

As I say, there seems to be no hard and fast rules about it, you might get stopped, you may not. I've never been stopped, but I know people who have.

I have heard this too, and by the sound of it, it is a case of anything- so no winch bumpers of any sort.... I will have to just stick to the back roads

It is going to be more of a weekend toy than a daily runaround

Glyn

23rd May 2011 9:26pm

XS Pete

Member Since: 13 Jan 2011
Location: Suffolk
Posts: 632

Quote:
It is going to be more of a weekend toy than a daily runaround

Nice one! I don't know how long your stay is likely to be but enjoy the island. It's a fantastic place with (in the main) great people, excellent food and reasonable beer. Have a Keo for me if you're out there soon. I'm not out there again until July!

Pete

23rd May 2011 9:42pm

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