Hi Flint,
Thanks for the advice on the needle bearing. I tried to clean it using your approach but unfortunately it was too seized to do any good and I could not save this bearing. A friend of mine helped me to remove the old bearing today and we have fitted a brand new one in its place.
A few of the Warn sellers here in England I spoke to have never needed to replace a needle bearing before because they are pretty much indestructable as i understand unless you do what I did and fill it with media sand.
If anyone needs advice on removing this bearing and refitting please let me know as we found a great method that took very little time and put no stress on the casing.
He also kindly used his digital calipers to help me set the lower drum bushing to .190 as required. We used a little threadlock material to hold it in place (recommended by a Warn seller in the UK), what did you use to hold your bushing in place Flint? Also does it matter if it moves at all once the drum is in and working as it won't really be able to go anywhere I guess.
I have painted the drum tonight with black Hammerite satin black spray paint and it looks great and like new. I am wondering if it is worth spraying a clear satin laquer on top to help protect the finish but i am not sure yet. It really depends if i can afford synthetic winch rope or if I go with the standard steel cable route. I will definately use the laquer with the steel cable to help it wear a little better.
Just the motor casing to spray now next week and re-assembly can commence at last.
Thanks, I shall post a picture of it once it is all finished.
Regards
Simon