refurbishing the wiring of an AI-1000 Aisin winch, including connectors, and devising a wireless remote

[John Young]

So here is a bit more. I became concerned that the main power solenoid will rust up unless it is protected. It came from the factory with a rubber boot, long gone, over the exposed plunger. My solution was to find a spray can top of the right size, cut it up and then use heat shrink tubing to seal it up more or less.

I also sprayed in a bit of silicone lubricant on the plunger before sealing it up. That should keep it lubricated just a bit.

 

[John Young]

BTW, I found that if I loosened the cap on the solenoid by removing the two screws holding it on, and then knocking the phenolic a bit, I could dunk the whole thing in Evaporust to clean up the plunger and anything inside. I then rinsed it out well with water, shook it out, and then liberally rinsed it out again with brake cleaner several times to remove the water. This really seems to have worked pretty well.

And tonight I finally got around to working a bit more on the substitute wireless controller.

It is not going to be really watertight but should be good in a light rain. I still need to decide how to secure the box to the bumper when it is plugged in.