It came to be that I needed to use the trailer to move some furniture. In case you didn’t see or don’t recall here is a link to see the damage.
Time to repair it, or alternatively pony up $500 or so bucks to rent a truck to get from Chicago to home. The pictures can do most of the talking, but the basic process was as follows:
- I used it in its broken state a bit, so I first had to clean out enough stuff to be able to work inside. I also had to source the roof bows. It so happened that my mother and nephew were traveling by the manufacturer about a week and change before I needed the trailer so I asked them to stop and pick up said roof bows. They were cheap, about $20 a piece.
- I started by figuring out how it was assembled. Basically the roof is a big section that connects 2 corner pieces together and runs the length. It’s lapped and sandwiched together with some light pieces of laminated board inside. I removed all the screws and laminated board so that I could get the roof bows out. You can see in the pictures where I had to peel up some foil to get to the screws.
- I went from front to back cutting out 1 roof bow at a time and replacing it with a new one. I started by supporting the roof off the bow, cutting the bow in the center, it basically fell out with a bit of twisting and bending after being cut in half. I then had to clean the welds on the top plate so that the new bow had a nice place to sit, then I just slid the new bow in place. Wash, rinse repeat all the way back.
- Somewhere along the way when I was bored I cut out about 2 feet from the rear of the roof. This was the section that wasn’t going to be usable anymore and needed to be replaced. I also did my best to straighten out the parts that got kinked in the back corner.
- I propped the new roof bows up high and pulled them down so that they had some good tension. I then welded them.
- Originally the sandwich on the edges was the only thing that kept the roof bows from twisting into and away from each other. I added a third row right down the middle to increase strength. I also used 2×4 instead of the smaller laminated wood to further prevent possible twisting. I think that the original construction was probably adequate, however since I’m not an expert I figured I’d be best served by adding as much meat as I could to prevent this from happening again. I started by placing the separating structures down the top-center, then moved to the side that had come unglued the least and did the side that had separated quite a lot last so that I could do my best to pull it all tight during final assembly.
- Before finishing step 6 I sourced and cut to fit the new rear of the roof. It was 4 foot in length and I only cut out 2 feet so I had a nice overlap.
- Once the whole thing was structurally sound I crawled up on top and used that really shiny really sticky duct tape to make a seal over all the screw holes and at the seams.
- As a last and final protectant I used roof repair sealant everywhere I could. At the edge of all the tape seams and also at the metal seams in the mid section of the trailer and at the tail end.
Anyways, that’s the shortwinded version of how I spent almost the entire week prior to labor day weekend. Enjoy the photos.
The seam in the back corner, this is where it all started.
The seam in the back corner, this is where it all started.19-Aug-2014 18:33, Motorola XT912, 2.4, 4.6mm, 0.004 sec, ISO 100
Another view of what I started with.
Another view of what I started with.23-Aug-2014 09:40, Motorola XT912, 2.4, 4.6mm, 0.004 sec, ISO 100
Before new roof bows - it looks someone wadded up a piece of paper then partially straightened it back out again.
Before new roof bows - it looks someone wadded up a piece of paper then partially straightened it back out again.23-Aug-2014 09:40, Motorola XT912, 2.4, 4.6mm, 0.006 sec, ISO 100
This is the remnants after removing the original roof bow, it was nice of the manufacturer to weld only on one side so they removed easily.
This is the remnants after removing the original roof bow, it was nice of the manufacturer to weld only on one side so they removed easily.23-Aug-2014 11:49, Motorola XT912, 2.4, 4.6mm, 0.02 sec, ISO 132
After cleaning up and ready to have the new roof bow placed.
After cleaning up and ready to have the new roof bow placed.23-Aug-2014 11:56, Motorola XT912, 2.4, 4.6mm, 0.01 sec, ISO 141
The sacrificed portion of roofing.
The sacrificed portion of roofing.23-Aug-2014 12:10, Motorola XT912, 2.4, 4.6mm, 0.002 sec, ISO 100
After removing the section of roof that had to go.
After removing the section of roof that had to go.23-Aug-2014 12:10, Motorola XT912, 2.4, 4.6mm, 0.004 sec, ISO 100
The most mangled part that I had to save.
The most mangled part that I had to save.23-Aug-2014 12:19, Motorola XT912, 2.4, 4.6mm, 0.006 sec, ISO 100
A view from the top, after I turned it into a convertible.
A view from the top, after I turned it into a convertible.23-Aug-2014 12:56, Motorola XT912, 2.4, 4.6mm, 0.003 sec, ISO 100
This was as good as my hammer and 2x4 body shaping tools could get it.
This was as good as my hammer and 2x4 body shaping tools could get it.24-Aug-2014 09:53, Motorola XT912, 2.4, 4.6mm, 0.009 sec, ISO 100
About halfway through replacing the old roof bows with straight/true new ones.
About halfway through replacing the old roof bows with straight/true new ones.24-Aug-2014 10:52, Motorola XT912, 2.4, 4.6mm, 0.033 sec, ISO 214
A look at the makeshift temporary support I had going on while I cut out the twisted roof bows.
A look at the makeshift temporary support I had going on while I cut out the twisted roof bows.24-Aug-2014 11:00, Motorola XT912, 2.4, 4.6mm, 0.029 sec, ISO 100
Another view of the most pretzeled up of the roof bows.
Another view of the most pretzeled up of the roof bows.24-Aug-2014 11:00, Motorola XT912, 2.4, 4.6mm, 0.035 sec, ISO 100
The mangled wreckage.
The mangled wreckage.24-Aug-2014 11:39, Motorola XT912, 2.4, 4.6mm, 0.008 sec, ISO 100
A nice low view of the new roof bows as they're being installed.
A nice low view of the new roof bows as they're being installed.24-Aug-2014 11:40, Motorola XT912, 2.4, 4.6mm, 0.041 sec, ISO 107
6 of the 7 roof bows in place, but not yet welded. I left the last one out as it would be exposed to the elements had I not.
6 of the 7 roof bows in place, but not yet welded. I left the last one out as it would be exposed to the elements had I not.24-Aug-2014 12:09, Motorola XT912, 2.4, 4.6mm, 0.018 sec, ISO 100
Picture as things are coming together. This is at the point where 6 of the 7 roof bows were installed inside and it was preparing for transport to my house where I'd finish the project.
Picture as things are coming together. This is at the point where 6 of the 7 roof bows were installed inside and it was preparing for transport to my house where I'd finish the project.24-Aug-2014 12:10, Motorola XT912, 2.4, 4.6mm, 0.001 sec, ISO 100
The sheet of aluminum that patched the tail end of the trailer. A full sheet cost me $43.
The sheet of aluminum that patched the tail end of the trailer. A full sheet cost me $43.26-Aug-2014 16:14, Motorola XT912, 2.4, 4.6mm, 0.001 sec, ISO 100
Interior is about 75% done, this picture taken as I called it a night the night prior to departure for Chicago.
Interior is about 75% done, this picture taken as I called it a night the night prior to departure for Chicago.29-Aug-2014 20:37, Motorola XT912, 2.4, 4.6mm, 0.1 sec, ISO 151
The finished product from inside. Note the 4 new LED lights, they ended up being a quite nice upgrade.
The finished product from inside. Note the 4 new LED lights, they ended up being a quite nice upgrade.30-Aug-2014 11:24, Motorola XT912, 2.4, 4.6mm, 0.014 sec, ISO 100
The finished product.
The finished product.30-Aug-2014 11:40, Motorola XT912, 2.4, 4.6mm, 0.002 sec, ISO 100