Lewmar ocean series electric upgrade caution

Jun 1, 2009
1,845
Hunter 49 toronto
This will only apply to a small section of owners, but I’m putting it out there nonetheless.
I upgraded all my Lewmar winches to electric, and it’s made life easier. Did the install myself, which wasn’t the hardest thing to do if your skills are at that level.
I’ve since helped a number of people convert their Lewmar ocean winches as well.
This subject is for anyone who has purchased the conversion kit in the last 2 years for any size of winch.
There is a critical 8mm square key which locks the motor drive shaft to the winch spindle.
While helping to install my buddy’s 2 conversion units, something stuck out immediately. The keys were carbon steel zinc plated; not stainless.
I confirmed this many ways, including the magnet test, scratching off some of the plating, etc.
These keys are a very tight fit, as the winch is high load, and instantaneous acceleration. Any slop in the key would gall up the keyway.
Any surface corrosion on this key would literally lock the shaft to the spindle, and there is no way to get spay lube in there.
Getting the drum off for regular cleaning & maintenance could be a fiasco.

I contacted Lewmar, and discussed this. It appears that the keys were no-stock, and I’m assuming someone in production just got an alternative that was available. Currently, the keys are still on back order.
I was going to get these machined, but was looking at $250 for 2 of them. Before you jump out of your seats, this makes sense. You can only get 8 mm stainless square stock in 1m length ($150 plus tax), and thus has to be done on a Bridgeport. This isn’t a hacksaw job.
I looked at buying ready made keys, but up at 8mm, you can’t get square; only rectangular. This makes sense, as keyways in the machinists handbook (holy bible of all things metal), specs keyways 8mm and larger to be rectangular. I assume that the shear force calculations dictate this.
So, got back to Lewmar, who back ordered keys for me.
So.. if you’ve done an ocean series motor conversion, it might be an idea to check the 8mm key: especially if you’re in salt water
 

RitSim

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Jan 29, 2018
457
Beneteau 411 Branford
I looked at McMaster.com. The interesting to see that 3 keys are only available as undersize. for the price quoted above, i would consider an 8 mm x 10mm key and hand fit the width of the key by filing or milling. The width undersize is only .001" (.036mm) by ordering the 8 x10 size, you get the opportunity to had fit the width multiple tries for $8.00 plus shipping.
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Jun 1, 2009
1,845
Hunter 49 toronto
I looked at McMaster.com. The interesting to see that 3 keys are only available as undersize. for the price quoted above, i would consider an 8 mm x 10mm key and hand fit the width of the key by filing or milling. The width undersize is only .001" (.036mm) by ordering the 8 x10 size, you get the opportunity to had fit the width multiple tries for $8.00 plus shipping.
View attachment 213988
Hi.
A agree that you can’t get 8x8. If “crack master” doesn’t have it, you aren’t going to find it
Filing the key isn’t viable. Youll never get it flat, and it will be sitting on a hump. With upgrade kits that cost $3500 each, you expect to have the right parts
Getting back to milling
If you’re throwing this on a Bridgeport, you might as well just get the 1 m length.
You can band saw it to length, and it’s a 2 minute cleanup .
Either way, this isn’t convenient, and shouldn’t be necessary for gear purchased through retail channels.
I’ve had nothing but the best of quality from Lewmar over the years. They have been taken over by Taylor, which is a conglomerate of some huge company who apparently owns the moon as well. (It’s in their annual report)