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08-31-2024, 12:06 AM
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#1
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2 Rivet Member 
2022 22' Caravel
Los Angeles
, California
Join Date: Jul 2022
Posts: 22
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Zip Dee Awning Bent Pin
I have a 2022, 22ft Caravel which I absolutely love. Just finished another trip and noticed something upon putting my manual awning back in its stow position for transport. One of the pins seems to be bent, not too sure how this could have happened and it does not appear to be affecting operation at all but does look a little suspect to me and the pin on the other side of the awning is perfectly straight by comparison. I have included a few pics below, please let me know your thoughts on what I should do and what parts specifically would be needed to fix this item.
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08-31-2024, 04:24 AM
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#2
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Site Team

1994 25' Excella
Waukesha
, Wisconsin
Join Date: Sep 2020
Posts: 6,365
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My guess is that to replace this you'll have to replace the end cap of the awning tube. Not a difficult job, but if it's the end of the awning holding the spring tension you'll have to first release all the tension. Possibly the pin itself is replaceable on its own.
A single call to Zip Dee will get their professional advice though, and I'd strongly suggest you do that first thing. They are VERY responsive to customer calls and can help set you on the correct path quickly.
__________________
Richard
11018
1994 Excella 25 'Gertie' Follow the build on Gertie!
1999 Suburban LS 2500 w/7.4L V8 'Bert'
1974 GMC 4108a - Custom Coach Land Cruiser 'The Bus' (Sold)
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08-31-2024, 04:50 AM
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#3
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2 Rivet Member 
2022 22' Caravel
Los Angeles
, California
Join Date: Jul 2022
Posts: 22
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Quote:
Originally Posted by richard5933
My guess is that to replace this you'll have to replace the end cap of the awning tube. Not a difficult job, but if it's the end of the awning holding the spring tension you'll have to first release all the tension. Possibly the pin itself is replaceable on its own.
A single call to Zip Dee will get their professional advice though, and I'd strongly suggest you do that first thing. They are VERY responsive to customer calls and can help set you on the correct path quickly.
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Thank you for the response and I’ll make sure to reach out to them directly.
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08-31-2024, 08:11 AM
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#4
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Rivet Master 

2017 26' Flying Cloud
Tampa
, Florida
Join Date: Feb 2017
Posts: 8,117
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I went online to find the roller parts.
Here's the exploded diagram. Looks like the part you seek is call the 'idler end shaft'. The end is attached to the roller using some pop rivets from the side, perhaps covered by your fabric.
Looks like you can replace all the end or just the shaft. Is the off center caused by wear since the shaft is stationary as the roller spins?
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08-31-2024, 10:27 AM
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#5
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2 Rivet Member 
2022 22' Caravel
Los Angeles
, California
Join Date: Jul 2022
Posts: 22
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Quote:
Originally Posted by Mollysdad
I went online to find the roller parts.
Here's the exploded diagram. Looks like the part you seek is call the 'idler end shaft'. The end is attached to the roller using some pop rivets from the side, perhaps covered by your fabric.
Looks like you can replace all the end or just the shaft. Is the off center caused by wear since the shaft is stationary as the roller spins?
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Thank you so much for looking into this and I’m sure you are correct in saying that the part I need is the idler end shaft. I will likely order a new end comprised of all the various parts including the shaft and attempt to replace it myself.
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08-31-2024, 12:03 PM
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#6
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2 Rivet Member 
2006 30' Classic
Bullhead City
, Arizona
Join Date: Dec 2008
Posts: 63
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Following. I have the same issue, please let us know what you learned and how the repair went.
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08-31-2024, 12:03 PM
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#7
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Rivet Master 

2017 26' Flying Cloud
Tampa
, Florida
Join Date: Feb 2017
Posts: 8,117
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I went back to your photo and marked what I thought was the rivets. You can drill out two while the awning is closed, but you'll have to open it enough to roll 180º for the other two. Maybe a box or something to hold it open a few inches.
I think the spring is at the other end, but I'm no expert, and I can testify you do not want to be hit with a flying end cap.
Epiphany: Maybe that's why they call the front end the "IDLE" end assembly. DOH.
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08-31-2024, 12:54 PM
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#8
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2 Rivet Member 
2022 22' Caravel
Los Angeles
, California
Join Date: Jul 2022
Posts: 22
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Quote:
Originally Posted by Reno Classic
Following. I have the same issue, please let us know what you learned and how the repair went.
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Will do for sure.
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08-31-2024, 01:00 PM
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#9
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2 Rivet Member 
2022 22' Caravel
Los Angeles
, California
Join Date: Jul 2022
Posts: 22
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Quote:
Originally Posted by Mollysdad
I went back to your photo and marked what I thought was the rivets. You can drill out two while the awning is closed, but you'll have to open it enough to roll 180º for the other two. Maybe a box or something to hold it open a few inches.
I think the spring is at the other end, but I'm no expert, and I can testify you do not want to be hit with a flying end cap.
Epiphany: Maybe that's why they call the front end the "IDLE" end assembly. DOH.
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Thank you again for looking into this & I’ll get a definitive answer from Zip Dee or Airstream before attempting this.
Included is a pic from our last trip, I can’t quite express how much having this Airstream and the experiences that it has brought has changed life for the better & given me a greater appreciation for what I have & ultimately how little we need in this world to be happy providing we’re lucky enough to have our health.
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09-05-2024, 05:25 PM
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#10
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2 Rivet Member 
2022 22' Caravel
Los Angeles
, California
Join Date: Jul 2022
Posts: 22
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Turns out what I noticed and I assumed needed repair is in fact normal and necessary as per Zip Dee for the awning to operate correctly. They explained if the shaft was rigid and straight without the ability to move the awning would not be able to operate as it does and the reason the other side appears straight by comparison is due to the fact there is a spring on that side so it’s under tension but it does also move and does not stay straight per say. The movement is necessary given the different positions the awning can be in from stored to open and everything in between so thankfully it’s all good and it was my OCD kicking in - lol
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09-05-2024, 08:00 PM
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#11
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4 Rivet Member 
2014 27' FB International
Lewisville
, Texas
Join Date: Sep 2015
Posts: 309
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Interesting, thank you for the follow-up.
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09-07-2024, 10:42 AM
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#12
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2 Rivet Member 
2006 30' Classic
Bullhead City
, Arizona
Join Date: Dec 2008
Posts: 63
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Thanks for the update. Surprising... but good to know this is normal.
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09-08-2024, 02:24 PM
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#13
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Man of means by no means
2023 28' Flying Cloud
Midland
, Georgia
Join Date: Jun 2016
Posts: 131
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Good to know!
Quote:
Originally Posted by kingsolomon
Turns out what I noticed and I assumed needed repair is in fact normal and necessary as per Zip Dee for the awning to operate correctly. They explained if the shaft was rigid and straight without the ability to move the awning would not be able to operate as it does and the reason the other side appears straight by comparison is due to the fact there is a spring on that side so it’s under tension but it does also move and does not stay straight per say. The movement is necessary given the different positions the awning can be in from stored to open and everything in between so thankfully it’s all good and it was my OCD kicking in - lol
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I haven't observed it yet on ours, but maybe I'm only 50% OCD. My DW might have a differing opinion though.
Thank you for the followup!
__________________
~~
The universe is expanding so that should thin out the traffic.
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09-09-2024, 11:31 AM
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#14
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3 Rivet Member 
2023 23' Flying Cloud
Carroll
, Iowa
Join Date: Apr 2024
Posts: 152
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Quote:
Originally Posted by kingsolomon
Turns out what I noticed and I assumed needed repair is in fact normal and necessary as per Zip Dee for the awning to operate correctly. They explained if the shaft was rigid and straight without the ability to move the awning would not be able to operate as it does and the reason the other side appears straight by comparison is due to the fact there is a spring on that side so it’s under tension but it does also move and does not stay straight per say. The movement is necessary given the different positions the awning can be in from stored to open and everything in between so thankfully it’s all good and it was my OCD kicking in - lol
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I almost made a comment to this effect in the thread because I have observed the exact same situation on my own awning on the right side - and I had heard/read elsewhere that this is a "feature not a flaw"... but I didn't want to risk passing out misinformation. So - glad to hear confirmation from ZipDee on this, thanks for posting your follow-up!
__________________
2023 Flying Cloud 23FBT ➕ 2024 F150 XLT PowerBoost ⚡️7.2kw⚡️ ➕ 2010 Border Terrier 🐾
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