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Better downhaul winch with handle for windsurfing — zdjęcie 1
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Better downhaul winch with handle for windsurfing

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Redesigned downhaul winch for windsurfing

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Printables
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After playing around with the basic downhaul winch design it was apparent it could be improved.  The main improvement is the basic design could fail under high loads due to the torque applied tending to separate layers of print so added 4 through bolts to stop any chance of this occurring.

Added handle so your fingers aren't holding the mast extension near the high tensile cord which also makes it easier to apply the downhaul in general.       Made the post 12.1mm diameter and printed to snugly fit the extension.   Need 4x M5 x 80mm bolts and nuts, 1 x 100mm M8 bolt and nut and 90mm of M8 threaded bar (or 8mm dia steel) to go through the post.   Glue the threaded bar inside the post.  Use stainless bolts where possible or paint them to keep rust to minimum.

The handle is same as previous design made from 10mm steel tube.   My tube was plastic coated.   Allow at least 120mm for the cord to wind on (i.e. 170mm straight section).  Drill a hole approx 1cm from the end for the downhaul rope.  You can bend the tube using simple pipe benders here: https://www.printables.com/model/492898-pipe-benders-for-10mm-tube-and-small-radius

The exact dimensions of the handle itself are not critical but roughly 20cm crank length is about right.