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GreatPumpkin · 07-12-2006, 11:42 PM

The top and bottom mounting brackets are what I need. If they're not available, I wonder how hard (or expensive) it would be to machine some out of a piece of solid aluminum? That would probably be a big improvement over the original cast metal mounts. Does anyone on the forums have a setup to recreate some mounting brackets?

I'd like to stay with the original for two reasons:

1) No new holes in the outer shell; re-use the existing mounting holes.

2) I already have it, and I'm a cheapskate (that's what my wife is always telling me - or was that tightwad, penny pincher and a few other choice words?)

CaddyGrn · 07-12-2006, 11:45 PM

We lost our awning when we owned a (SOB = some other brand) in a previous life. Once we were on the road into Yosemite and a big rig came around a narrow corner and we had no where to go but nearly into the guard rail... well, our awning bracket ripped off. Always had trouble with it after that it seemed... another time (after this incident) we were on Hwy 101 near Salinas in California and the wind was really blowing... just caught our rolled up awning just right and opened her up right on the freeway just like a sail.... that was interesting too.

But we all survived. At least in yours and ours no one got hurt. As much as we love our little homes on wheels, can't compare to our families!

How was your shower drain? I know you had an incident at Silver Falls... did that work out?

Don calls the insulation located in the bellypan area (where all the water can leak) Airstream diapers.

We have a metal lathe... Don loves to play around on it... so his offer to help you fabricate potentially needed parts.... who knows! Talk to him... He isn't an expert this huge thing in our garage didn't become part of our "family" until retirement.

It was great to meet you and your family ~ please tell your bride her brownies were wonderful!!!!

We hope to see you at another forum rally! Maybe Beverly Beach in the winter!

Mrs. NorCal Bambi (Claudia) Traveling in S Tardis

GreatPumpkin · 07-12-2006, 11:53 PM

Quote:

Originally Posted by CaddyGrn

...

How was your shower drain? I know you had an incident at Silver Falls... did that work out?

Don calls the insulation located in the bellypan area (where all the water can leak) Airstream diapers.

It was great to meet you and your family ~ please tell your bride her brownies were wonderful!!!!

We hope to see you at another forum rally! Maybe Beverly Beach in the winter!

Mrs. NorCal Bambi (Claudia) Traveling in S Tardis

I haven't had a chance to tackle the drain yet. It appears that the upside down "bowlers hat", that on some trailers hangs below the belly pan to acommodate the p-trap, on mine is contained completely in the belly pan with no access. I'm going to have to cut an access panel in the belly, remove the "bowlers hat" and then replace the p-trap. It probably froze and cracked from the PO's failure to winterize. Fortunately the water was contained within that part and didn't go into the airstream diaper

.

Thanks. I will pass on the compliment to my better half. It was a pleasure meeting you and Don. Is there a date set for Beverly Beach?

GreatPumpkin · 07-13-2006, 08:44 PM

Quote:

Originally Posted by GreatPumpkin

...

The mounting brackets appear to be cheap, cast “pot” metal.

I stand corrected; The brackets are cast metal, but while removing and cleaning them for phot ops, I discovered they are aluminum! Every part of the awning is aluminum except a steel arm that slides out to extend the awning, and a few large steel rivets. Here's some pic's if anyone has them to spare, knows where to get replacements, or knows someone who can recreate them.

till · 08-15-2006, 11:39 AM

Is the serch still on?? If so, can you get me a measured drawing of the original and a quanitity???

GreatPumpkin · 08-15-2006, 12:39 PM

Quote:

Originally Posted by till

Is the search still on?? If so, can you get me a measured drawing of the original and a quantity???

The search is still on.

I have 2 broken ones, but if I am able to find someone to create them, I'd probably get 4 to keep the aesthetically the same (and to prevent future failure/breakage in the other 2)

Overall length is 4-1/4"
Overall height is 1-5/8"

Shaft length is 1-1/2"
Shaft thickness is 25/32" (20mm)

Base length is 2-1/4"
Base thickness is 1/4"

Body length (minus shaft) is 2-3/4"

Mounting holes are 1/4" spaced 7/8" apart (center to center)

The drawing isn't that good, but you should be able to get the general idea. I can send one to anyone able/willing to replicate.

till · 08-15-2006, 02:05 PM

Give me a couple of weeks.........

till · 08-21-2006, 06:58 AM

couple of questions...
How much weight is on this part?

Does it have to look just like the original or can it be beefed up a little?

GreatPumpkin · 08-21-2006, 07:17 AM

They are pretty light weight aluminum. 3-1/8 ounces per bracket (92 grams). It could probably stand a little "beefing" up so the awning doesn't go road surfing again. The mounting holes and length are the main things so I (preferably) don't have to put any new holes in the shell of the AS.

till · 08-21-2006, 08:52 AM

Sorry, I was not clear in my first question. How much weight will be on the bracket? Working with the engineer here we have come up with a little more square design, but to refine it he needs to know the load on it. Mounting holes and spacing will remain the same.

GreatPumpkin · 08-21-2006, 02:19 PM

Sorry, I guess I should have read the question better

Definitely unscientific in my measurements (I used a bathroom scale), but the upright arms weigh about 15lbs each. It takes one bracket at the top and one bracket at the bottom of each upright/arm. The cross piece the arms attach to is almost 30lbs.

I'm sure there is some mathematical equation that says when the awning is extended that the weight each bracket supports changes, but I wouldn't even know where to begin on figuring that out

GreatPumpkin · 08-21-2006, 02:25 PM

Picture to help explain?

NorCal Bambi · 08-21-2006, 02:41 PM

Great Pumpkin, Sounds like Till has the resources and knowledge to remake the part you need. I have a suggestion after seeing where your parts broke. If the screws will still fit with the modification I'm making, They won't look too different. Just a thought.
Don

till · 08-21-2006, 04:14 PM

That is just what I need to know and see. Thanks!

overlander63 · 08-21-2006, 04:15 PM

I have searched my garage, and don't have any extras of the parts you need. Hopefully Tedd's solution will work.

till · 09-07-2006, 11:49 AM

OK, sorry about the delay. I should have a PDF to post for approval this evening. Modeling shows a 12X safety factor with 100 lbs load.

till · 09-07-2006, 12:11 PM

OK so it didn't take as long as I thought...

Let me know what you think.

GreatPumpkin · 09-07-2006, 02:40 PM

Quote:

Originally Posted by till

OK so it didn't take as long as I thought...

Let me know what you think.

Almost - I guess I should have used a less ambiguous term than “shaft”. I was referring to a shaft in the male sense, as in a driveshaft, vs your rendering shows a shaft in the female sense, as in a mineshaft. The shaft slides into the upright arm of the awning at the top and bottom.

Looking at your rendering, and referring to the 4 drawings, I’ll call the top left #1, top right #2, bottom left #3, and bottom right #4.

Drawing #1
o The first hole from the left should be centered at .50 from the edge instead of .55 (the .875 between the holes is correct)
o The overall width is currently 1.125 instead of 1.5 (although wider width will work)
o If changing the overall width to 1.125, then the .75 measurement would be .5625 instead

Drawing #3
o The 2.5 measurement should be 2.75. The remainder of the overall length of 4.25 should be the male shaft. It is 1.5 in length, with a thickness of .781

till · 09-07-2006, 08:23 PM

To make, making the part easier, I am going to press a pin in the hole that you pointed out.

I tried (working with the pictures and engineer) to come up with a compromise that would work out best.
Drawing #1 I can move the holes down the .050 if you need.
Drawing #2 The length differeance is due to the angle. To make a angle that is easier to machine the length changed. The over all should still be the same. i.e. from the bottom mounting hole to the top where the pin will be inserted.

Also, the material will be 6061 aluminum with the machined surfaces left as machined. The pin I am not sure about just yet. I am thinking brass or maybe just some aluminum rod turned to the right diameter.

Does this help clear up your findings??

GreatPumpkin · 09-07-2006, 09:11 PM

Quote:

Originally Posted by till

To make, making the part easier, I am going to press a pin in the hole that you pointed out.

I tried (working with the pictures and engineer) to come up with a compromise that would work out best.
Drawing #1 I can move the holes down the .050 if you need.
Drawing #2 The length differeance is due to the angle. To make a angle that is easier to machine the length changed. The over all should still be the same. i.e. from the bottom mounting hole to the top where the pin will be inserted.

Also, the material will be 6061 aluminum with the machined surfaces left as machined. The pin I am not sure about just yet. I am thinking brass or maybe just some aluminum rod turned to the right diameter.

Does this help clear up your findings??

I think that clears it up, except the overall length? Currently the 4.25 length includes the shaft (or pin). If you machine it as pictured, then insert a pin that would increase the overall length by 1.5? Which would then require mounting the brackets further away on the airstream. That would put the top bracket further up the curve of the airstream body, changing the angle at which it sits. Or am I missing something?