12 volt winch driven York air compressor build

[thenag]

Over the next winter the bronco will be no more and we will begin stuffing the good stuff from the bronco into a 99 xj. The more research I do on the xj and the more I look at it I realize that keeping the a/c, adding a second battery and putting a york under the hood either isn't going to happen or is going to be so tight that it will really really suck. (Which is going to be a real new thing for me since my bronco has a 460, 2 batteries, a belt driven york, spare driveshafts, spare master/slave for clutch, a d-60 hub socket, and still has the OEM air box...)

So my father in law made a comment about putting an electric motor on a york, then I remembered I had a spare winch motor, then I remembered I had broken husky pancake compressor. So I snagged (another) york from tear-a-part.

I also came across this thread
http://board.marlincrawler.com/index.php?topic=64942

At this point this build is kind of a prototype or proof of concept. If this becomes something we keep on the future xj it will be re-built and some higher quality parts will be used.

I had to destroy the york pulley to get the inner shaft so I could use it as a spacer between the mcmasterarr part and the york shaft

so this is how they will be coupled together (gravity helped to pose this picture)

Hopefully I will have time and the rest of the parts to get this functioning and see how many amps it pulls over the weekend or by next week. (hopefully...)

album is here;
http://picasaweb.google.com/thenag/12vYork?authkey=Gv1sRgCNvCueChgYLXrwE#

Nathan
87 Bronco, 460, d-60, gm 14bolt, 37 old mtr's, 6500lbs of pig... (for now)
http://www.supermotors.net/clubs/superford/users/ylobronc/registry/194

 

[Dave_Couch]

Good writeup Nag, by the way are you going to treat your YJ like you did your bronco with a spare one of everything bolted to the underside of your rig? BTW thanks for the spare steering gear box when mine busted on the RIM.

dc

 

[thenag]

Good writeup Nag, by the way are you going to treat your YJ like you did your bronco with a spare one of everything bolted to the underside of your rig? BTW thanks for the spare steering gear box when mine busted on the RIM.

dc

Carrying spare parts and tools on the xj will be an issue for me, I didn't really think of the bronco as having that much space until I started to look at how little the xj really is. Especially since I want keep the back seat. Having a useful back seat, I have realized, is very important when you have to leave a rig on the trail to go get parts... I still have no idea where I am putting the spare drive shafts on the xj.

This of course is a whole different thread lets keep this one on the home brew Oasis...

Nathan
watch for our xj "pre-build" thread coming soon... I promise...

 

[Tacoma]

So where is this going to be mounted?

 

[thenag]

At this point I actually want it to be portable like the Oasis. I have Anderson style forklift connectors on my Bronco and my f250, when we build the jeep it will have them as well. My father in law also has them on his hunting truck.

I got the bracket tack welded today, I should be able to finish welding the bracket tomorrow.

Nathan

 

[Deweyxj]

I've thought about doing something like this for awhile! I allways thought a starter motor would get to hot for this kind of application!

i'ld be very interested to see how this turns out, because I also know how hard it is to fit extra stuff under the hood of a Cherrokee, or for that matter, any late model SUV!

 

[thenag]

Well crap.

Winch motor free spinning pulls about 55 amps

Winch motor directly hooked up to york pulls about 180 amps

Winch motor hooked up to york, york hooked up to tank run up to about 40 psi, motor pulls over 200 amps

I don't have a way to figure out how many rpms the york is going but it seems to fill up the tank faster than what the belt driven york on my bronco does, of course that has some reduction due to the pulley system and the engine is usually at idle when I am running the york...

This would work for filling up tires, so long as you had two batteries and some really high amp solenoids.

I will try to post a few more pictures tonight, right now I am thinking about how to get some gear reduction...

Nathan

 

[thenag]

Well I pieced together a gear box from some Pierce winch parts I had laying around.

Filling a tank to 50psi it was pulling about 130 amps. Still high but not "kill your electrical system horrible" (well provided you have 2 batteries and a high amp alt)

So I didn't need the motor couplers from mcmastercarr ($35.00 wasted) and I didn't need to destroy the york pulley (hopefully I don't ever need another york pulley)

This was a temporary setup, I probably won't be able to improve upon my design until next weekend.

Album still here;
http://picasaweb.google.com/thenag/12vYork?authkey=Gv1sRgCNvCueChgYLXrwE#

I will post up the Pierce part #'s I end up using, their parts are pretty cheap.

Nathan

 

[thenag]

Well this setup should work. I can live with 130 amps, hopefully it will go down a bit with some oil in the gear box.

Pierce does not seem to list the gear box housing on their website.

They do have this kit that includes all the parts I used ($127.99) (except the motor and motor pinion gear) (this does have a few extra parts)
http://www.piercesales.com/ProductD...&eq=&desc=PS654-K-Transfer-Housing-Kit&key=it

motor ($102.99) (this is a pretty universal motor from what I understand so if you have a spare winch motor laying it *should* work)
http://www.piercesales.com/ProductD...vy-Duty-Motor-for-PS654-series-winches&key=it

motor pinion gear ($13.29)
http://www.piercesales.com/ProductD...eq=&desc=PS654-Series-Motor-Drive-Gear&key=it

(that may or may not have the woodruff key included, if not the key is $.29)

I had all this stuff laying around so that is why I used it.

Maybe someone can educate me on figuring out gear reduction, here goes my thoughts... The pinion gear has about 1/3 the teeth as the gear I have driving the york so is that about 3:1 gear ratio? The motor spins about 2500 to 3000 rpms (lets say 2700rpm for simple math). The way I have it setup 3:1 the york should spin about 900 rpms.

Does my "math" check out?

The setup on my bronco has a small pulley (Kilby) on the alternator driving a larger pulley on the york. I have no idea how fast the pulley on my alternator spins at idle... so yeah no clue... My gut says that if the pulley on the york is about the same size as the pulley on the crankshaft they should spin about the same speed regardless of all the other pulleys in the system, so I am guessing that my york on the bronco spins about as fast as the crankshaft. so call it 900 rpm's at idle.

Any thoughts?

Am I way off base on figuring out the ratios? Not that it really matters I am not going to do anything about it.

I have been working on a plate/cover for the gear housing, I will probably be able to post some more pictures tonight.

Nathan

 

[ricsrx]

That is a cool idea!!!

 

[thenag]

More progress made...

Made a plate to mount the york to the gear box out of scrap steel... really rusted scrap steel...

I welded on some flat steel to pick up the 4 front mounting bolts on the york and added a handle.

The plate I made replaces this little plate and o-ring from the york, some silicon should seal it up.

I had to cover a hole on the gear box, I used a big piece of angle which gave me a nice little place to put the switch and solenoid.

Wired it up... incorrectly and the motor wouldn't spin.

got on google (I love having an old computer in my garage, and thank you pirate...) Just in case you didn't know, to get a 3 post winch motor to spin you need to jumper the armature (terminal furthest away from the front of the motor) to one of the field terminals, and then put 12v to the other field terminal. (I had the power going to the field I that I had jumper-ed to armature). Correct is; F1 to armature, 12v to F2. or to spin the other way, F2 to armature, 12v to F1.

It spins pretty good, don't have any of the air side rigged up. I still haven't decided if I want to mount it on an old pancake air tank I have or not. I will have to borrow an amp clamp again and do some further testing. The solenoid that I have is 90 amp continuous so it really shouldn't last long since this thing pulls about 135 amps.

It is leaking oil from the gear box, so I will have to sort that out too...

I need to put a fuse on this thing, it would suck for the york to seize and fry the electrical system on the vehicle it is attached to.

I'll update more as I do more...

full album is still here;
http://picasaweb.google.com/thenag/12vYork?authkey=Gv1sRgCNvCueChgYLXrwE#

Nathan

 

[MikeGyver]

Maybe this is what I will do with my york.
Should use a small block cheby (double) roller timing chain.

 

[thenag]

I found one of those here;
http://www.pirate4x4.com/forum/showpost.php?p=6929120&postcount=15

thread is here
http://www.pirate4x4.com/forum/showthread.php?p=6929120#post6929120

He claims he was going to do thread on that setup but I couldn't find it.

Nathan

 

[thenag]

I got some more work done, and few more parts. It is all setup on a freebie air tank with a pressure switch, safety pop off. If Napa is open tomorrow I am going to get a 150 amp fuse and then run the thing for a while and see what happens. It is really heavy, not at all a practical portable compressor. But as I said at the beginning it is the prototype...

full album is still here;
http://picasaweb.google.com/thenag/12vYork?authkey=Gv1sRgCNvCueChgYLXrwE#

Nathan

 

[thenag]

Got the fuse and holder today;

Got it running tested it a bit. Filled my 37 from 13 psi to 30 psi in under 2 minutes.

Nathan

 

[thenag]

I swapped the pressure switch with the one in the bronco. The Husky pre-set 95/125 will be fine on the belt driven york on the bronco...

The one I had on the bronco is adjustable but it has been under the hood of the bronco for like 10 years so it is really dirty I think when I clean it up I can get it dialed in better. I was trying to get about 70/90 but it doesn't like being set that low so it looks like I should be able to get 60/100psi. I really don't want to buy another pressure switch right now so I will tinker with it some more and see what happens.

The good news is that I ran the 12v york up to 100psi probably half a dozen times trying to set the pressure switch and it ran fine. It hasn't burnt up the 90 amp solenoid yet or the 150 amp fuse (remember quick testing with an amp clamp showed about 130 amps so yeah doing fine with that... for now)

It is a pretty loud setup. I have always described my Pierce winch as "perfect for the bronco, heavy, loud, slow, leaks oil and really really powerful" This motor and gear box are almost as loud as the whole winch, add that with the typical york noise and you almost need ear plugs.

Nathan

 

[thenag]

A quick video of me running the air down to about 50psi, the pressure switch kicking on and it running up to about 95psi

http://picasaweb.google.com/thenag/12vYork?authkey=Gv1sRgCNvCueChgYLXrwE#5498421177655485634

Nathan