Jim, before you spend a lot of time and money replacing batteries and
buying a new charger , etc. , you really should check out your winch motor
( actually you are checking out the system , which includes the cables and
the selenoid 's ) . The "cheap way" to do this is to borrow a Current Meter
from your local service station , preferably one that is closed on Sunday.
You return it on Monday Morning with  a Dozen or so Donuts , or Bagels ,
etc. ,and you will make their day.
Get as many of your club members to show up at your flying site on that
Sunday, we want a variety of planes. As each Pilot hooks up , write down
their name and what they are launching . As they are Launching , write down
the current draw, maybe a couple of times if they do a zoom. 
What you are looking for is a "pattern" , Gentle Ladys should produce a low
current reading , Pedal to the Metal  3M  Contest Planes should produce
much higher readings. After about 20 or so launches do a "Temperature Test
" on the cables and the motor , and don't forget the short one between the
selenoid and the motor. The cables should be warm but not Hot. If they are
hot then you have a problem. Either the motor is drawing too much current
or the cables are too small.  I use 2/0 welding wire cable because it very
low resistance even at 200 amps, and even after 20 hard launches it's
barely warm. Because of the way it is made , thousands of small strands of
copper wire , it is very flexible , so you will never have to worry about
breaking individual stands.   If the Motor is really hot , you should
really check that too. In most cases a competent automotive shop should be
able to tell you the "Health" of your starter motor with the drum attached
, just remove the line.  He will know if the motor is ok in about 10
seconds. Once again Donuts and/ or Bagels work wonders here.  Two other
things to keep in mind , if you are relying on the simple bronze bushings
in the starter motor , you are going to delevop a great deal of drag soon
after you start using the winch. Either add and outboard ball bearing to
the drum , or bite the bullet and purchase a set of Doug Boyds Real Balls
end bells. If you are using a 6 volt motor then naturally your current draw
will be higher than for a 12 volt motor. That will effect your battery
life.      
The biggest problem with using 6 volt Trojans is Logistics . At the end of
the day you have two "tired" batteries and one slightly "tired" battery. 
You have to keep swapping batteries so that they get equal use as a
retriever battery , and as  1/2 a winch battery. With only three batteries
one is always working hard two times in a row. 
Obviously there is no excuse for buying a cheap charger and then blaming
the batteries for poor performance. The big problem with many of todays
batteries is that they have sealed them up so that trying to check them
with a Specific Gravity Gage is difficult .( you have to pry the covers off
to get access to the cells ) . The good thing about the Trojan  Industrial
cells is that they assume that you are going to have to add water to the
cells due to the high charge currents they have to endure , so they have
"old-fashioned " caps on the cells .
Ok  I'm done for now , somebody else finish this up .

Jim Bonk
  
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