PullPal Repair and Modifications

[Seanz0rz]

Back in the summer, I managed to break my PullPal. It was my fault, and not really the fault of the product. I was using it for something unintended. However, there are a few weak points in the pullpal.

This thread is here to describe what I did to fix it, and make it better. I talked (in person) to the owners, and they offered to fix it if I sent it to them. This was, unfortunately, cost prohibitive. I decided I could fix it myself with items I have available to me.

The failure occured in the small bolt that is used on the strut pivot. When that sheared, the plow took a different path from the connection to the winch line. this caused the top main pivot to twist horribly before I realized what had happened.

Here is the aftermath:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3666.jpg

Finally, I've found the time to fix it.

Better pictures of the plow beam damage:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3805.jpg
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3806.jpg
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3807.jpg
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3808.jpg
Continued on next post...

[Seanz0rz]

The ears were carefully cut off:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3809.jpg
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3810.jpg

The best one was flattened with a hammer to make a template:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3811.jpg
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3812.jpg

The original ears were only 1/8" thick. I made two new ones, with a modified weld line, out of 3/16". They were tacked into place:
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3814.jpg

I also replaced the ears on the other beam, they were much simpler and I didn't get pictures of those.

Next post for the conclusion!

[Seanz0rz]

Everything was tacked into place and once proper geometry was assured, it was welded up!
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3816.jpg
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3817.jpg
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3818.jpg
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3819.jpg

That is as far as I got today. I will be replacing all of the hardware, with at least grade 8 bolts. I am considering 9, but i think the steel would fail long before the bolt will.

As far as modifications go, I will be boxing in a significant portion of the area that previously twisted itself apart. A mod for another day...

Thanks for reading!

[corax]

Good job man :thumbup:

I feel like something's missing though . . . I thought every thread involving you and a welder had to have a can of Dr.P in it somewhere.

[Seanz0rz]

Good job man :thumbup:

I feel like something's missing though . . . I thought every thread involving you and a welder had to have a can of Dr.P in it somewhere.


i quit... it's been hard. now i just walk around with either iced tea strong enough to take the paint off a car, or ice water...



i didnt put it in the first post, but some of the weak links of the pullpal are: the unboxed ears, they fold easily! also, the bolt holes should be sleeved, and the sheer should never be applied to the threaded parts of the bolt. i know that is somewhat impractical to do, but this was the mode of failure.

i know someone is dieing to ask how i broke it. i was pulling bushes out of the back yard and used it to reverse direction with a snatch block. i dont think i exceeded the rating of the unit, but the pullpal caught a rock underground and pulled sideways. again, my fault, and i take full responsibility for it breaking. i have yet to hear of another one failing, and the owners of the business were shocked to hear it failed as well.

[Seanz0rz]

So now to the modifications.

I didn't take any pictures of the process, but here is the result (still needs paint)

http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3847.jpg
http://i955.photobucket.com/albums/ae38/hamiltonfabrication/PullPal%20Repair%20and%20Modification/IMG_3848.jpg

basically I boxed in what i could to strengthen the ears against folding.

I could go further and sleeve all of the joints, and use pins instead of bolts, but I think this will do just fine.

I sprayed the rusty bits with a rust converter. It's suppose to rain tomorrow, so I'll try to paint it Sunday or next week if it is warm enough.

Trying to figure out a way to mount it on my bumper, and it's such an odd shape I'm having a hard time with that. I will figure out something though...

Also, in the second picture, you can see the sweet bi-fold gate I built last summer! It's covered in tile dust right now.

[4x4mike]

Looking good. That thing looks bomber.

Good job on the fence too. That looks like quite the project.