Planning the shaft line assembly

I don't have any cad program or 3D design program to do the design in so I'm going to divide the problem into small pieces and hopefully not run into any issues down the line. Main problem to solve is the shaft line assembly, so let's start from there!  

I need to somehow connect this,



to this.


I have to admit I did not do my research well enough before purchasing the winch!  I was hoping there would be an output shaft from the planetary gear but there is only a gear wheel that connects / disconnects the winch drum from motor. The design is simple and smart but maybe not optimal for this kind of alternative use of the motor.




I have come up with tree alternatives witch all include using the winch drum as part of the shaft line. I am worried about the strength of the aluminum casting in the drum, so one important selection criteria is witch alternative I believe is most durable.

Alternative 1:

Local hardware store had correct dimension weldable bushing.


As I don't own a lathe I was thinking I could weld a bolt to the bushing to make a shaft. A concern is will I be able to get the shaft straight enough during welding to be able to use the shaft?


Drill a 14mm hole from the end of the winch drum to connect the pieces. 13,82mm is the outer diameter of the unthreaded part of bolt.



Another concern is the drilling of the hole from the end of the winch drum. The shaft is already hollow and has a machined slot at the end that might cause trouble if trying to drill by hand. A lathe would do a better job at drilling the hole!


Fixing shaft line assembly to be done in same way as the hand crank is fixed to shaft, with locking bolts.




Alternative 2:

 
The outer diameter of the winch drum at the nylon bushing is same as the outer diameter of bead roller shaft so it means that the weldable bushing could be used as such to connect the two parts together as shown in picture below.

 
My concern is that the "shaft" part of winch drum is so short so it will not be able to take the torque. One solution could be to use a lathe to modify the drum so the shaft part would get longer. Connect parts with locking bolts.






Alternative 3:

Use slot at the end of the drum to connect to the weldable bushing. Some welding and fabricating  would be required but no special tools like lathe or similar. from manufacturing point I believe this would be easiest. However I'm not sure this joint would be strong enough so I have more or less rejected the idea. 




 


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