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I have used a cotter key that just fits in with great success. I have no way to test the tinsel strength though. It maybe to strong. If it is I have been very fortunate. Has anyone tested a cotter key? That would be a cheap fix if it is safe.
Mr. Cranetruck, thank you for the info. Do you know the shear strength of this 2017 alloy? I found some 3/8" 2024T4 round stock and was hoping I could use this for my 5 ton and my deuce. (turned down for the deuce of coarse) It is my understanding that the 2024T4 material is used for the deuces...
AL 2024 T3 or T4 has a tensile of 68000 psi a yield of 47000 and most important (to us anyways) shear strength of 41000 psi. I have no idea if this is to much for these winches or not. So I am probably going to go with AL6061 T6 which has a shear strength of 30,000 psi. You can buy a 5/16" 3'...