ouR escaPOD mods

After spending a hefty sum of money to replace an axle that had lost its camber (out of warranty and Lippert did not offer to replace it like some have reported), I wanted to do something to help prevent this from happening again. This is my version of axle reinforcement. It is a work in progress and I will post further pictures when it is done.

Materials:  77.5" long 3" x 3" x 3/16" steel angle

                    I pack of miscellaneous lengths of steel square tubing, angles, etc. sold as a welding practice pack

                    1 3" length of 1.5" x 3/16" flat steel stock.

                    3 1/2" x 4" x 6-1/2" U bolts, washers, and nylock nuts.

Tools:  Harbor Freight wire-feed welder with auto-darkening face shield and various welding tools.

             Harbor Freight angle grinder with cutting and grinding disks.

             Drill and assorted drill bits

             Files, flat and round

             Gloss Black Krylon Fusion All in One Paint and Primer

             Some miscellaneous rags, denatured alcohol, etc.

             Logging chain rated at 2,600+  lbs

             12 ton rated bottle jack

The next idea was to cut pieces of flat stock to weld to the 3x3 angle and bolt to those. However, my welding skills leave something to be desired. Given the location, I sure did not want my welds to break while we were going down the highway and have the steel fall of an possibly kill someone. Plan A was out. However, since I had already welded tabs on to both ends of the angle but not the middle, I decided to do something different. I had some pieces of 1.5" x 1.5" steel angle in the practice pack along with some square stock. I decided that I would use some of the angle to sit opposite the reinforcing angle and weld the square stock to the angle to give me a piece that would not depend so much on my welds but on the tension of the bolts to hold everything together. I feel safer that way. The tabs I previously welded on will be used for spacing but they will not be holding anything. That will go to the square tubing welded to the angles for the top of the axle. The squares were cut to length and an angle cut out of them so that they fit the 1.5" x 1.5" angle stock pieces I had cut to length. Then the squares were welded to the angle so that they will pull toward the axle when bolted in place.

Here is what the fabricated parts look like:

The two pieces I made with the larger square stock will go on the ends. The one with the smaller bar stock will go in the center. I will be assembling this (hopefully) tomorrow once I get home from an appointment. My V block should also be good for lifting it up to the axle and holding it while I put the U bolts in the ends. Then I can remove the support and put the U bolt in the center.

I may defer installing for a day so I can clean and make sure the axle is painted with no rust spots. If I have to do any painting, that will take some time to dry.

The standard wire closet shelving at the big box stores is what we used.  However, it is a little bit narrow for the width.   As you can see from the pictures, we added a piece of 2x2 to the left edge of the shelves and they fit perfectly. The 2x2 was well sanded and rounded corners so as to not snag on our clothes.

If you want more pictures or close-ups, let me know in a personal email

Vann