Spring hanger torn off...probably my fault!

[working on it]

from e-trailer "expert" reply:

The movement of the suspension will make it almost impossible to keep the spring hangers tight to the frame if bolted, so we strongly recommend that spring hangers be welded into place. If you wish to also bolt them by running a bolt up through the frame and securing it from the top of the frame with a nut, you may do so but it is not necessary.

Kody- too late, its a done deal. If you saw my thread on "axle locator strap", you can see that I wanted redundant safety (in the form of a strap surrounding my axle), to hold it together long enough to safely exit the road. The same for the bolts thru the 1/4" angle holding the hangers in place. It's the angle that is really the new "frame", since the thinner original rectangular tubing already has been compromised by the breakage. I figured that the bolt through the hanger/angle interface would serve to momentarily hold it together (if the welds failed) long enough to exit the road safely. I did weld the spring hangers all the way 'round, like in this picture of a hanger with bolt-on plate base,

welded bolt-on.jpg (41.21 KiB) Viewed 1233 times

so I followed a manufacturers lead. Again, I still think the heavier gauge metal repair piece I am using, and the load sharing cross-braces to come, whether bolted or welded improperly, will be stronger than the original set-up.

[working on it]

Just done,

hanger assembly complete2 (1).jpg (106.25 KiB) Viewed 1201 times

now ready to order a new axle. Since I've been working tons of overtime lately, and with the addition of more steel and a heavier axle to the "already too heavy for my HHR to pull trailer", I'll go ahead and order an axle complete with electric brakes (which I previously hadn't thought necessary). The trailer will still be too heavy for the little HHR and Cobalt we have as daily drivers, but as retirement approaches, I am considering replacements for the "fleet" of vehicles we have. A small pickup or a small/midsized SUV could take the place of a couple of aging vehicles in the stable. And that vehicle would become the TV for this trailer, and possibly my wife's larger (but under 5k lbs) Puma trailer. Therefore, both trailers should have brakes. Now to find one, preferably locally sourced (I like to see what I'm getting before I hand over the money). My best options for that are Redneck Trailer (Dexter axles) 5 miles away, Southwest Wheel/Trailer Parts (Al-Ko axles) a short sidetrip along my route home from work, or Quality (Rockwell axles) 50 miles northwest or 70 miles northeast. I bought two axles from Quality (northwest) several years ago for my carhauler rebuild, but had to have my friend (welder) attach the spring seats. I do not want to try that myself (you see guys, I have been listening to your advice), since that is such a critical piece. Southwest Wheel/Trailer Parts also doesn't weld the seats on. I think that Redneck Trailer buys the Dexter axles custom-made with seats welded on at a factory, but a friend told me that it took 3 weeks to get it (about 10 years ago). I never get off work during the week until 8-9-10, and these places are closed on Saturdays, and I can't seem to find the time during my workweek to talk to them, so should I just order an axle online, pay the shipping, and hope I receive it in 2 weeks? What source have any of you received a custom-made axle from in that short time span? I've got to order real quick; my trip is in one month, and I have very little working time available. ???

[working on it]

...now ready to order a new axle. Since I've been working tons of overtime lately I'll go ahead and order an axle complete with electric brakes (which I previously hadn't thought necessary). Now to find one, preferably locally sourced (I like to see what I'm getting before I hand over the money). My best options for that are Redneck Trailer (Dexter axles) 5 miles away, Southwest Wheel/Trailer Parts (Al-Ko axles) a short sidetrip along my route home from work, or Quality (Rockwell axles) 50 miles northwest or 70 miles northeast. I bought two axles from Quality (northwest) several years ago for my carhauler rebuild, but had to have my friend (welder) attach the spring seats. I do not want to try that myself (you see guys, I have been listening to your advice), since that is such a critical piece. Southwest Wheel/Trailer Parts also doesn't weld the seats on. I think that Redneck Trailer buys the Dexter axles custom-made with seats welded on at a factory, but a friend told me that it took 3 weeks to get it (about 10 years ago). I never get off work during the week until 8-9-10, and these places are closed on Saturdays, and I can't seem to find the time during my workweek to talk to them, so should I just order an axle online, pay the shipping, and hope I receive it in 2 weeks? What source have any of you received a custom-made axle from in that short time span? I've got to order real quick; my trip is in one month, and I have very little working time available. ???

A neighbor suggested Nuera Trailerparts in Dallas (which is also a short side-trip along my route home from work), so I sent an inquiry via e-mail last Saturday, giving my specs (based on the Dexter ordering measurements, found on the Redneck site). A rep responded Monday, saying that Dexter could not build/weld one to my specs, and that I would have to extend my hub face from 61.25" to 63.75" before they would weld the spring seats on. After responding to that, by asking what spring center measurement would match the 61.25" hub face, he answered 47", on Tuesday. I am stuck with a 48.75" spring seat distance, having already built to that spec, so I dragged the wife out to the garage when I got home from work, to help me accurately measure wheel and hub face expansion alternatives. I had her hold a wheel vertically (using a square, for accuracy) with the tire at the maximum distance outward (while still under/inside the fender), while I measured the hub face gained from moving the wheel to that maxed-out position. Luckily, the Dexter-quoted 63.75" is exactly that! I measured this after getting home at 15 'til midnite, as the wife complained loudly, having roused her from bed! So, now ready to ACTUALLY order, I was unable to reach my sales rep for two days, then he promised to finalize the order, and I am still waiting after two more days. Another week lost. He had promised a 7 day turn-around, but now I may still have to make a new contact elsewhere, if no response comes Monday, as my ETTC (estimated time 'til camping) grows shorter. Time is my nemesis.

[48Rob]

Details and deadlines never play well together...

[working on it]

Details and deadlines never play well together...

Since I am in the "total disclosure mode" concerning my trailer building peccadilloes, I decided to use a molded 7-way RV plug/cable

hoppy 20146.jpg (27.55 KiB) Viewed 1147 times

http://www.northerntool.com/shop/tools/product_200312018_200312018 to upgrade from the 20+ year-old 4-way wiring harness I used in the build. I had to remove it from the frame channel when I drilled and mounted the frame reinforcements, so now was the time to upgrade and add electricity for the electric brake axle (still hoping to order it), and maybe on-road battery charging functions. Details and deadlines again. I bought the cable at Northern Tool; it came without instructions, but who needs them anyway? Color-matching, and taking care to properly crimp and use shrink tubing to weatherproof each of the connections....Whoa, there! About half-way into it, I decided to test some connections (actual turn signals, brake lights...) with truck plugged in. I never thought that the manufacturer (Hopkins) would change the trailer-side wire color codes from the matching truck-side connector (also a Hopkins product). Of course, I should've tested the circuits first, but my multi-meter and trailer plug tester are at my in-laws, and I just assumed....

[working on it]

Bought a new multi-meter to replace my lost 25+ year old Micronta, and another "tow vehicle-side 7/4-way tester". Confirmed that all was working (my stand-by multi-meter, though new, gave me intermittent readings...), so now I can run the new wiring, color conflict aside, by checking continuity by circuit, then by function when finished. Tried again today to order the axle; I was told to fax an "official" order form, but the receiving fax wasn't working. So, I guess I'll have to go in person to their office tomorrow, instead of having a lunch break, to get it done. Whatever happened to the ease of ordering thru e-mail, fax, or online? Details and deadlines are plaguing me like an albatross around my neck.

[Dale M.]

Unfortunately for us, many 7 way connectors do not have a standard wiring color..... Yes there is supposed to be a color standard for trailer wiring but manufactures don't seem to be aware of it for 7 pin pigtails... Yes its best to verify the wire colors against the "pin-outs" and then assign the wires accordingly... Colors are for people, electrons don't care what color the insulation is...


Another part that will help you along the way may be this....




http://www.etrailer.com/comparison.aspx ... &pc2=38656

Dale

[working on it]

Unfortunately for us, many 7 way connectors do not have a standard wiring color..... Yes there is supposed to be a color standard for trailer wiring but manufactures don't seem to be away of it for 7 pin pigtails... Yes its best to verify the wire colors against the "pin-outs" and then assign the wires accordingly... Colors are for people, electrons don't care what color the insulation is...


Another part that will help you along the way may be this....




http://www.etrailer.com/comparison.aspx ... &pc2=38656

Dale

Haste makes waste...just basing my 7-way cable wiring on experiences with 4 and 6 way (my 6 way on my car-hauler was like the 4-way, with blue added for brakes, and white for ground) was foolhardy. My other wiring experience comes from re-wiring or modding old cars (which always seem to have departed somewhere from the oem color scheme). That experience background should've made me look before leaping into the change-over. I had thought of using a terminal strip to join the wires (and even using another 4-way as a back-up for the 7-way), but didn't want to drill holes into the cabin or tonguebox to house the terminal strip in a weatherproof location. The 7-way sealed box in your link looks to be what I need. I will order one this week from E-trailer. P.S. I finally got the new axle ordered!

[working on it]

... Details and deadlines are plaguing me like an albatross around my neck.

That's not all that's plaguing me; peripheral bad luck always seems to strike. First, the good news: I received the wiring box today from E-trailer. Just perfect, can't wait to use it. Was informed today that the axle should be here Friday a.m. (OK, 10 days turnaround instead of 4-7 as promised, but I'll be satisfied to get my hands on it, whenever...). Now, the bad news: hidden water leak from crack in water heater tank or busted pipe (found both, not sure which caused the other, or just a coincidence) saturated the subfloor in two rooms, causing floor warpage but not structural (I hate inferior OSB subfloors = a water magnet). Guess what project takes priority?...not the trailer! Bought a new WH and backer boards and insulation (for under floor) tonight, and just by a serendipitous coincidence, a friend of my wife dropped by with her contractor/carpenter husband in tow. While I was at work, he inspected the situation and agreed to fix the big things > pipes, WH, cement backer board to shield new sub-floor, underfloor insulation (I am not a carpenter, and only plumb when forced to...usually by in-laws), and my wife and I will finish the flooring. I may still find time to install the new axle/wiring in a week or so.

[working on it]

Picked up the new Dexter 3500 lb axle, with EZ lube hubs, and electric brakes, this afternoon. My wife's friend's husband completed the subflooring and underlayment repairs today, also. Woo-hoo! half-finished on two worrisome projects. I might still be able to make Beaver's Bend after all. I also arranged to take off the whole week before then, having only scheduled two days previously (don't want to have a last-minute crisis with no time to resolve it).

• new axle
• electric brakes now
• EZ lube hubs/spindles
• specifications tag
• big ticket item #37 or so

Should've just bought a new utility (or cargo, or factory-built TD) trailer on day one...but then, where's the challenge/anguish of the building? As usual, I'm working on it....

[working on it]

Spent all afternoon yesterday wiring up the new Hopkins 7-way molded plug/cable to the Spectro 7-place wiring junction box. To get the length needed to extend the plug 2-ft past the coupler (needed to reach the receptacles on both my trucks), and to run the 8-ft cable (needed the 11-ft version, not at Northern!) inside my single-drawbar tongue to the cross member where I had mounted the wiring box under the trailer, I had to splice in 2 feet of 4-way (ground, right-turn, left-turn, and tail) wiring cord to match the different color coding on the 7-way (made a diagram so I wouldn't repeat the earlier errors). Then, for the remaining three wires (brake, backup, and 12v accessory), I used some leftover 14ga cable (I marked each wire as to function, on both ends) and used weatherproof(shrink tube-type) butt connectors , then more shrink tubing overall, and secured them in place in the drawbar. Then, I crimped ring terminals on all the 7 wires, and ran them to the corresponding terminal inside the Spectro box (marked as to function by the manufacturer). I ran another white 12ga wire from the box to the crossmember, and used a self-drilling screw to secure it, as a ground. Finally, I tied in the existing 4-way trailer lighting wires using new connectors and more ring terminals. Then, I used another leftover 14ga cable to extend the wiring from the Dexter brake wires, again using the shrinkable butt connectors, and more shrink tubing over them. As it was now dark outside, and I was at a stopping point, I put the new axle in the garage (I had left it in the bed of my truck overnight, as it was a convenient workbench of sorts), intending to install it today. If it stops raining, that is! I do have to comment on using the Spectro junction box...easy to install, and why didn''t I use one before? I intend to re-wire my carhauler (from a 6-way plug to a 7-way), before I next use it, and this box will make it easy. Update: added pics after finished wiring

box open, before brake cable added

Photo20140413_164613.jpg (88.43 KiB) Viewed 985 times

and

closed, with brake wiring added

Photo20140413_164613a.jpg (76.4 KiB) Viewed 985 times

[working on it]

It stopped raining, so I jumped back on the project immediately...finished the wiring, and lifted the axle into place. Tightened all nuts (after staking the bolts in place) to the hangers by hand to fully tight, then backed off a 1/4 turn, so I would not repeat the mistake either I or someone else made by overtightening with an impact. Put on the wheels, and saw that the tread just barely fit under the fenders (but the sidewall bulge protrudes an inch)...this would pass inspection at the dragstrip, so I presume as long as the tread is under the fender it's OK for street use.

Photo20140413_200156a.jpg (72.43 KiB) Viewed 988 times

Previously, I had very little frame to tire clearance, now a lot

Photo20140413_200156.jpg (65.72 KiB) Viewed 988 times

Here's a pic of the curbside

Photo20140413_195944.jpg (81.8 KiB) Viewed 988 times

Now to test it out....

[Redneck Teepee]

I would think that as long as the tread is covered you will be fine. Looks good by the way, you are on the road to recovery so to speak.

[aggie79]

WOI,

Looks like your're good to go. We hope to see you and meet you at Beavers Bend.

Take care,
Tom

[working on it]

Thank you both; I hope to make it to BB, but once again, my wife may have to be out of town on that weekend, and I'll have to stay home to care for the WildBunch-our 7 dogs, who act like a pack, and can't/won't be handled by neighbors or relatives- (just like when I couldn't sign up for the LCGVIII, though I told- yes, told!- her to reserve that date for my use). However, this time she'll be working, not socializing. I'll keep my hopes up, though. I've done a lot of work to rehab the suspension in a short time; shame if the extra effort would be for naught.