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At our summer cottage, motor boats were prohibited many years ago and, when I visited a surf shop named "Shark" a salesman made me aware that it was possible to use a wake board winch that simulate the cable park and that cost around $ 2100, I could then continue practicing wakeboard. I searched on the Web and ask my friend if it was a good idea and then I finally decided that I had to build my own winch for wakeboarding that could also be used for urban snowboarding.

After two summer , I finally finished my wakeboard winch project , I am 15 years old and this was my first big project.

Wake winching :

Winch is the popular term today, is a growing hobby for many water sports enthusiasts. It consists of an engine, spool, rope, handle, frame, and some sort of simple transmission. The person being towed walks (or swims) away from the winch and pulls out all of the rope. When the winch is engaged, it pulls the boarder usually between 15 to 25 miles per hour (24 to 40 km/h). Winches are popular for people wanting to board on ponds and lakes, or just don't have a boat. Also, the winch can either be mounted on the trailer hitch of a vehicle, set into the ground by stakes, or tied to a tree. These winches have also been modified for use by skiers and snowboarders in cities.
http://www.norwegian.com/magazine/features/2014/01...


- By doing a lot work and after a lot of efforts to build the winch, I learned how to do my own research, all the calculations , the testing all by myself and I also learned how to use AutoCad drawing software that also help me create drawings and various plans. I learned a lot through all that.

- I had access to a sand blast cabinet, to presses, presses drill, grinders, sanders, jig saw, puller, torq wrench (engine), professional bink and devil devilbiss air spray gun, epoxy primer and professional polyurethane two composite paint, acetylene torch, stick/mig/tig welder and other tools from the mechanics servicemen of my father tools and equipment rentals business.

-You absolutely must have: jig saw, any type of welder, grinder (sanding, cutting and grinding disc), metal paint, screw driver, wrench, hammer ... and other basic tool

You need :
1-Engine (over 7 hp if you don't have torq converter )
2-Metal square tube
3-Spool (you can build it like i did or purchased one on ebay for 250-300 $
4-Engine clutch, chain, sprocket( i used # 41-42 + you must choose the gear ratio depending on the sport you practice),fairlead ----------The Clutch, sprocket, 41-42 chain, fairlead, steel hub were all from mfgsupply.com with a total cost of 272 $. Shipping cost is not included and others parts like the bearings came from various ebay supplier
6-Rope

7-Lexan, bolt....http://www.homedepot.com




Step 1: Welding Frame and Drills Holes

-The steel frame was fabricated using square tube and was mig welded



Step 2: Paint the Frame

-For best results, use polyurethane paint with epoxy primer
otherwise
- Buy antirust paint at Home Depot

Step 3: Engine Installation

- Attached to the frame with 4 bolts

Step 4: Spool Fabrication

-The spool were cut out from a .125 in. (1/8) steel plate – and it is designed to allow settings of 6.5”, 8.5” and 10.5” (The plate was first cut with a niblers then to make it perfect it was trimmed with a Bosh 6” disk sander at low speed rotating the spoll over a center shaft — Using a jigsaw wasn’t successful to cut the steel plate without burning and breaking the blades and using acetylene torch to manually cut the plate wasn’t accurate for that type of job)

Step 5: Spool Installation

Step 6: Attach the Chain

-Information about chain classification , the chain number isn’ t the same thing then the sprocket number of theet :http://jleibovitch.tripod.com/id240.htm

-To determinate the number of teeth on the sprocket and the clutch ,you need to do some calcul.

-The number of teeth you want for the sprocket depend of the engine specs and the speed you want to go . A regular ratio is normally around 5:1 or 6:1 but it also depend of the spool inner diameter and your engine capacity.

-This is the formula for MPH-KM/H wakeboard winch theatrical speed:
1-Pi (~3.1416) × spool setting diameter = circumference.
2-Sprocket teeth / clutch teeth = gear ratio
3-Engine RPMs / Gear Ratio = sprocket RPM (revolution per minute of the sprocket)-(smaller the ratio is ,faster its going to go but with less torque , and bigger the ratio is , slower it will go but it will have more torque.)
4-Sprocket circumference in feet × sprocket rpm = (?) feet per minute.
Conversion:
5-Feet per minute × 60 = feet per hour.
6-Feet per hour / 5280 = (?) miles per hour.
7-miles per hour × 1.61 = wakeboard winch spool speed in km/h

Step 7: Lexan

Step 8: Throttle & Kill Engine

-Gaz throttle and kill engine switch are on the command control box ( always safety first ) .

Step 9: Apply Decals

Step 10: Rope

information about the rope :

-I actually tested the winch with a 1000′ nylon rope (sbn rope ) because of the low cost. I am now going to replace it with a 1000′ of 1/8 dyneema rope supplied by www.barry.ca

-Attach the rope and rewind

Step 11: Have Fun !

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Bio: Mikael Ravary
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