How did you wire the limit switches and how are they mounted?
The winch comes with a cable-in limit switch on the frame. There is a rigid metal loop through which the cable passes that is hinged to the winch frame on one side. A small lever on the loop presses a momentary action (normally closed) switch (button) when the metal loop is pushed up against the frame by a large, round weight that came pre-attached to the wire rope, just above the hook (see the enlarged photo on the
Harbor Freight website).
However, I removed the weight when I cut the wire rope. So, I simply attached a small piece of metal flat stock to the metal loop (using zip-ties, of course). There's a small hole in the flat stock through which the wire rope passes. A cable clamp was attached to the wire rope at the right spot so that it hits the flat stock, which moves the loop on the hinge which presses the built-in limit switch button and stops the winch just as the boat reaches the desired upper limit. I’ll try to remember to take some pictures or a video and update this post later. It’s much easier to show than it is to describe.
There was no cable-out limit switch provided, so I had to start from scratch. Electrically, it was simple. The fun part was figuring out how to pull it off using only the parts I had on hand that particular Sunday afternoon — my goal was to avoid yet another trip to Home Depot. The end result looks like something straight out of
Southern Engineering Magazine, but it works like a charm.
I found an old double-pole, double-throw (10A) toggle switch in a tool box drawer. I’m pretty sure it’s been there since Abe Lincoln was in office, but it worked like new. I mounted the switch (toggle pointing downward) to the screw-drive support of the garage door opener using a home-brewed L bracket. A small hose clamp was used to attach a short piece of 1/4” fuel line to the toggle, thus extending it to the required length. The end of the fuel line was bevel cut such that it just makes contact with the garage door opener’s screw-drive carriage each time the door is opened or closed. When the door opens, the switch is toggled and it breaks the cable-out circuit. When the door closes, the switch is toggled the other direction, closing the cable-out circuit. I slathered a little bit of axle grease on the end of the fuel line to ensure that the carriage slides by smoothly.
Is it pretty? No. Elegant? Hardly. Functional? Yup. Reliable? 100%, so far.
Total cost: A six pack of Dos Equis Lager, one lime, some miscellaneous garage junk, and a several hours of my precious time. Mission accomplished!
Again, I’ll try to get some photos or a video posted later. They should be good a for a few laughs.