Convert Manual Winches to Electric With Brand-Specific Conversion Kits

Muscle fatigue mid-tack doesn't announce itself. It shows up quietly, usually when you're short-handed in 20 knots and the genoa sheet has stopped moving. Converting your manual winches to electric is no longer a superyacht proposition: brand-specific kits from Lewmar, Harken, and Andersen mean you can work with your existing hardware, use the same deck holes, and still do most of the job yourself.

Why the conversion is worth taking seriously

Electric winches are becoming more popular because they make shorthanded sailing much easier, allowing crews to hoist and trim any size sail in all kinds of conditions, simply by pushing a button. That's not just a comfort upgrade. Electric winches make high-load jobs easier by allowing the user to look up at the main while hoisting, to make sure there are no snags or hold-ups. That awareness dividend alone justifies the project on any boat sailed regularly short-handed.

Electric winches offer smoother, more consistent tensioning for sails and lines, and while there's an upfront cost, an electric winch can boost resale value and reduce physical wear on the user. For anyone planning to hold onto their boat for another decade, that math adds up fast.

Can your existing winch be converted?

The honest answer is: it depends on brand, model, and age. Modern winch conversions are making it easier than ever to shift from manual to electric operation, but whether you can convert will depend on the model and age of your winch.

For Harken owners, Harken has two main winch ranges: Radial (2009 to present), which can be converted from 35.2ST models upward, and Classic, which can be converted from size 44 and larger. One particularly useful detail for Radial owners: manual Radial winches easily convert to electric or hydraulic power, and they don't require an adapter plate; the identical stud pattern means you don't have to fill old holes and drill new ones.

For the Harken Radial range, any winches from 1999 onward can be converted, though it will depend on what type of winch you are looking to convert because the years can vary. Critically, winches must be in good condition before conversion; it is necessary to make sure your winch is working well. Don't use a conversion kit to rescue a worn-out drum.

Andersen offers the broadest size coverage of the three brands. Converting your winch from manual to electric motor-driven operation is easy using Andersen's electric conversion kits, which are available in either E1 single speed, Electric Two Speed, or Compact Motor Variable Speed power units; they can be fitted to most modern Andersen winches ranging from size 28ST to 110ST and are available in 12V or 24V.

The above-deck vs below-deck decision

This is the choice that shapes the entire installation, and it deserves more thought than most guides give it.

The Andersen Compact Motor is available in two formats for either above-deck or below-deck motor placement. It is a brushless DC motor carefully matched to a low-profile planetary gearbox which requires less space for installation and draws considerably less current than traditional motor/gearbox configurations; available in 12V and 24V models, Compact Motor electric winches operate at variable speed in proportion to the pressure applied to the push button, for smooth and quiet operation.

Below-deck placement is the traditional route and keeps everything mechanical out of the elements. The trade-off is access. The prospect of drilling new holes in your boat, using more power, and taking up valuable space below deck can put people off. That concern is real: anyone who has tried to bolt a heavy gearbox to a coupling above their head in a cramped cockpit locker knows the challenge.

With horizontal (left/right) or vertical configuration options available for most sizes, it's easier than ever to fit an electric winch with minimal space sacrificed below deck. For cabin top winches specifically, the Harken UniPower 900 single-speed electric winch has a motor that is partially embedded inside the drum and extends only 105mm (4-1/8") below the base, giving crew more headroom as well as space to move around.

Above-deck placement solves the below-deck space problem entirely. With a low-profile above or below deck motor, installation is possible even if the original boat design did not allow for space under the deck for a motor. For Andersen's Compact Motor kits specifically, the unit is extremely easy to install and maintain, integrating the motor, gears and power control into one compact unit with no extra control box necessary.

Walking through the conversion: what the job actually involves

For a Lewmar Ocean or EVO-based installation, the sequence follows a logical pattern that any competent boat owner can manage with patience and a helper.

One of the main components of the Lewmar conversion kit is a base plate with a 2¼-inch outer diameter flange that extends through the boat's coachroof or deck; your converted winch will sit on this baseplate, which also houses the shaft seal and drive shaft. Another major component is a new winch center stem that houses all the winch's gears and bearings; this stem bolts to a set of threaded holes in the base plate, an arrangement that allows you to remove the winch for servicing without having to disconnect the baseplate, motor and driveshaft.

The EVO range adds a useful option for sizes 40 to 50: the contactor can be pre-mounted to the motor gearbox, removing any complicated wiring for a more tidy and easier installation. In that configuration, it only requires connecting the battery and the switch supplied. Worth noting: decks thicker than 34.4mm will need an extension kit. Check that measurement before ordering.

For the wiring run itself, route the power cables from the battery or power source to the electric winch location, use marine-grade wiring to resist corrosion, and secure the connections with waterproof connectors while sealing any openings with marine sealant.

The Lewmar kit also ships with its own electrical safety components: the conversion kit includes a 90-amp breaker, a "contactor" solenoid switch, and a deck switch. Budget some additional material costs: expect to spend between $300 and $400 above the cost of the kit for wires, connectors and bolts, and this is a full two-day job.

For Harken Radial conversions, the motor-to-drivetrain integration is tight and efficient. All Harken standard powered winches drive through the winch's 2-speed transmission; Harken motors attach directly to the drive shaft so the gears turn the winch, resulting in less drain on the battery with a smaller, more efficient motor. Evolving technology has enabled the new Dual-Function Control Box to incorporate a built-in load controller, reducing wiring and simplifying the circuit, which also allows more flexibility in where the control buttons can be mounted.

After installation: testing and maintenance

Don't skip the load-free test. Once all connections are made, test the electric winch without load first; verify smooth operation, then test with a light load to ensure everything is functioning correctly. When attaching the motor and gearbox to the winch drum, ensure proper alignment to avoid gear damage and confirm the rotation direction aligns with manufacturer guidelines.

Routine upkeep is minimal but matters. Regular inspection means checking for corrosion, loose connections, or worn parts every few weeks; for lubrication, use manufacturer-approved lubricants on gears and bearings to reduce wear.

Choosing the right kit

The kit has to match your winch model exactly, not just the brand name. Andersen, Harken, and Lewmar each publish size-specific part numbers, and MAURIPRO carries the full range for all three brands, with kits available in both 12V and 24V configurations and in above-deck or below-deck variants to suit whatever your boat's layout allows.

Installation is straightforward with all kits including everything needed to do-it-yourself, or have your preferred yard do it for you; a comprehensive installation manual, templates, push button, and cable terminals are provided in every kit.

The conversion turns what is currently a two-handed, braced-at-the-winch chore into a task any crew member can handle from anywhere in the cockpit. For a passage-maker or a solo sailor, that shift in how loads get managed is, in practical terms, a change in what the boat can do.