The Problem
We have four electric winches on our boat. While we keep them covered when we're not sailing, rain can enter through the winch handle hole whenever the covers are off — running straight through the winch internals.
Everything inside is either brass, stainless steel, or plastic, but that doesn't prevent surface rust from appearing, and that water could eventually lead to leaks. It would be best to just prevent water ingress entirely.
The Requirements
Every good design begins by stating the requirements to fully explore the problem. In this case, they're straightforward:
- Prevent water from entering the winch handle hole.
- Easy to install and remove so a winch handle can be used without hassle.
- No interference with motor operation.
Our winches have a motor cut-off pin that gets pushed down when a winch handle is inserted, disabling the motor. The cap must prevent this pin from being depressed.
The Solution
I designed a simple plug that fits snugly, removes easily, has a wide rim to deflect rain, and includes a hollow recess that allows the cut-off pin to extend upward without being pushed down.
The Design
As is typical for marine 3D-printing projects, the material chosen was PET-G. It is naturally resistant to UV and water, easy to print, and can tolerate significant impact — meaning it should last.
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| Winch Cap in ViaCAD 2D/3D |
The Print
Printing four caps takes roughly 2 hours and 50 g of material, with about 20 g consumed as temporary support for the overhangs. After printing, the support structures are simply broken free and disposed of.
This print could have been done upside-down, substantially reducing the support needed. However, that approach would have left considerable scarring on the most visible surface once the support was removed.
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| Simulation of Printing with Bambu Studio |
Finished Product
The winch cap has been a great solution, effectively preventing any water ingress into the winch.
A version with a built-in grip on top was tested but proved unnecessary — it's easy enough to grab the cap by its sides — so the grip was removed for a cleaner look and nothing to catch water.
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| Winch Cap in use |
Want one?
Interested in your very own winch caps? They are available for $4 each plus shipping. Where I ship from changes all the time, so reach out for a quote.
