Winch to solenoid connection

[KingLeonidas]

So I just installed my Ford Perfomance Winch. (Really nice setup) Anyway, I figured it would be a good idea to wire it to a solenoid so I could kill power using an AUX switch.

So I had to bore out the center of the warn power O-Ring connector for it to fit on the Stinger 500 solenoid. Afterwards I wondered if that was a bad idea? Did I make it less able to pull the full amount of amps by boring the center out a few mm? Curious on others thoughts or what they did themselves. TIA everyone!!

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[SierraBronco]

Bringing @CalvinT into the thread

 

[CalvinT]

So I just installed my Ford Perfomance Winch. (Really nice setup) Anyway, I figured it would be a good idea to wire it to a solenoid so I could kill power using an AUX switch.

So I had to bore out the center of the warn power O-Ring connector for it to fit on the Stinger 500 solenoid. Afterwards I wondered if that was a bad idea? Did I make it less able to pull the full amount of amps by boring the center out a few mm? Curious on others thoughts or what they did themselves. TIA everyone!!

How much metal did you remove? What size was the hole before you bored it out, and what size drill did you use? And how much metal remains?

You probably should have cut the old connector off and used the right size connector for the stud on the solenoid.

Later this evening I'll look up the winch and Stinger and see if there's any documentation.

 

[Brian_B]

Post a pic

You are probably ok unless the ring is like… hanging by a prayer

The official answer is “oh hell no, cut it off and recrimp the right one” though.

 

[KingLeonidas]

So I added two photo. The one with the post is the ground but the post measured at 1/4 and the other one measured at 5/16. So essentially I bored the hole from 1/4 to 5/16. Yes, I thought about just cutting this one off and crimping on a 5/16 connector but decided to see if this would work or not.

 

[CalvinT]

Looks OK to me. If you want to be sure, run the winch on a heavy load while touching the connection. If it's not too hot to touch you're good to go.

 

[SierraBronco]

So I added two photo. The one with the post is the ground but the post measured at 1/4 and the other one measured at 5/16. So essentially I bored the hole from 1/4 to 5/16. Yes, I thought about just cutting this one off and crimping on a 5/16 connector but decided to see if this would work or not.

Send it bro!

 

[CalvinT]

So I added two photo. The one with the post is the ground but the post measured at 1/4 and the other one measured at 5/16. So essentially I bored the hole from 1/4 to 5/16. Yes, I thought about just cutting this one off and crimping on a 5/16 connector but decided to see if this would work or not.

I took another look at your photos. I'd lose the split lock washer. They add resistance and don't really do anything. Just make sure the bolt is tight, not "farmer" tight and the cable doesn't move.

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