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Notes on my Aliner Expedition modifications including carrying ebikes on the back

mike All Messages By This Member #104410 https://alinerexpeditionmods.blogspot.com/
Steve T All Messages By This Member #104411 I put 2 regular bikes on the back of my Chalet Alpine (mid sized trailer).? This trailer has 4" beams - what is considered to be "strong". After about 7 years of using it that way, the main longitudinal beams sagged, the door gap became wider, and the top roof contact point when folded started crawling forwards.? That was quite the expensive problem to fix.? I tried getting it fixed at a whole bunch of places, and nobody except one was willing to touch that repair.? The one place that did it would not give any guarantees.? ? So be careful when you start putting weight on the rear bumper.? It's not just the bumper that can break.
Don DeRyke All Messages By This Member #104412 Good info.? My 2009 had those issues.? When I decided I needed to replace the entire floor, I did a frame off restoration.? I had already fabricated and installed a 2" receiver with two cross bars welded to the 2 x 3 frame.? I also straightened the frame by pinning it's midpoint under my garage beam and jacking up the rear about 7" to remove a 3/8" dip.? I then welded a pair of 6' long, 1-1/2" x 3" channels to the frame over the axle.? I think I'm good for now.? LOL. toggle quoted message Show quoted text On Sat, Feb 1, 2025 at 22:17, Steve T via groups.io <srtimm@...> wrote: I put 2 regular bikes on the back of my Chalet Alpine (mid sized trailer).? This trailer has 4" beams - what is considered to be "strong". After about 7 years of using it that way, the main longitudinal beams sagged, the door gap became wider, and the top roof contact point when folded started crawling forwards.? That was quite the expensive problem to fix.? I tried getting it fixed at a whole bunch of places, and nobody except one was willing to touch that repair.? The one place that did it would not give any guarantees.? ? So be careful when you start putting weight on the rear bumper.? It's not just the bumper that can break. -- Don DeRyke Sunrise, Florida 2009 Classic, 2020 Ford Escape, 2.0 liter EcoBoost, AWD.? Previous TV 2015 Ford Escape 1.6 liter EcoBoost engine.
elegy3983 All Messages By This Member #104413 开云体育 ? Alas, been there, done that…? ? Back in 2013, we noticed the same symptoms of frame distortion (bending) under cantilevered loads mounted on the rear bumper, well aft of the axle. We published two DIY articles on this topic, a discussion of why it occurs and what to do about it. Hopefully, they will help: ? ? The requisite rebending of the frame and either welding in frame reinforcements and/or installing frame stiffening latches on the roof side extrusions should not be particular daunting for an experienced body shop to accomplish for you if they follow my articles. ? Best of luck,? Dave ? ? …………………….. ? I put 2 regular bikes on the back of my Chalet Alpine (mid sized trailer).? This trailer has 4" beams - what is considered to be "strong". After about 7 years of using it that way, the main longitudinal beams sagged, the door gap became wider, and the top roof contact point when folded started crawling forwards.? That was quite the expensive problem to fix.? I tried getting it fixed at a whole bunch of places, and nobody except one was willing to touch that repair.? The one place that did it would not give any guarantees.? ? So be careful when you start putting weight on the rear bumper.? It's not just the bumper that can break.
Steve T All Messages By This Member #104414 Dave, what I ran into when looking for a repair shop was they could do the welding, but they were concerned about the liability.? They don't want to charge a customer for a repair that they're not sure will work, or worst case have the frame break and cause an accident.? One place said the repair won't work because there's no structure above the door gap.? Another said welding to thin walled steel beams on small trailers was prone to stress cracking. Another place took the trailer for 2 weeks, and asked around through their network of buddies on how to do the repair, and eventually came back and said no they didn't want to fix it.?? The one place that eventually agreed to do the work did not want to do it originally, but finally agreed when I said either I get this work done or I scrap the trailer. ? ? On Sun, Feb 2, 2025 at 09:19 AM, elegy3983 wrote: toggle quoted message Show quoted text ? Alas, been there, done that…? ? Back in 2013, we noticed the same symptoms of frame distortion (bending) under cantilevered loads mounted on the rear bumper, well aft of the axle. We published two DIY articles on this topic, a discussion of why it occurs and what to do about it. Hopefully, they will help: ? ? The requisite rebending of the frame and either welding in frame reinforcements and/or installing frame stiffening latches on the roof side extrusions should not be particular daunting for an experienced body shop to accomplish for you if they follow my articles. ? Best of luck,? Dave ? ? …………………….. ? I put 2 regular bikes on the back of my Chalet Alpine (mid sized trailer).? This trailer has 4" beams - what is considered to be "strong". After about 7 years of using it that way, the main longitudinal beams sagged, the door gap became wider, and the top roof contact point when folded started crawling forwards.? That was quite the expensive problem to fix.? I tried getting it fixed at a whole bunch of places, and nobody except one was willing to touch that repair.? The one place that did it would not give any guarantees.? ? So be careful when you start putting weight on the rear bumper.? It's not just the bumper that can break.
elegy3983 All Messages By This Member #104416 开云体育 ? Steve: ? I’m surprised!? I had no problem finding a frame shop to do the welding.? In fact, after the initial weldment years ago to correct the frame distortion (which was so pronounced that the door “A” side would interfere with the apex of the front and rear roof halves because the roof hinges had spread apart due to the deformation), I was involved in a road rage accident two years ago that bent the tongue up about 10” as well as tearing up the door side of the camper.? I rebuilt my camper in my garage, except I hired a frame shop to force the tongue back into position and weld a steel reinforcement under it.? They accomplished this with no issues, and there has been no weld failures in either instance. ? Sorry you ran into weld shop issues… ? Dave ? …………………… ? Dave, what I ran into when looking for a repair shop was they could do the welding, but they were concerned about the liability.? They don't want to charge a customer for a repair that they're not sure will work, or worst case have the frame break and cause an accident.? One place said the repair won't work because there's no structure above the door gap.? Another said welding to thin walled steel beams on small trailers was prone to stress cracking. Another place took the trailer for 2 weeks, and asked around through their network of buddies on how to do the repair, and eventually came back and said no they didn't want to fix it.?? The one place that eventually agreed to do the work did not want to do it originally, but finally agreed when I said either I get this work done or I scrap the trailer. ?

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