Thursday, 19 July 2012

More Finishing Touches

After some deliberation we decide to move the location of the brake return springs. They used to act on the rod that exited the drum itself (top center of the picture) but the rod that goes from the lever to the balance bar is threaded, so provides a much easier solution for giving the spring something to act on. Basically we cut a 70mm length of 25x25 box metal in half, diagonally and drilled a hole in the top of the thin end of each 'wedge'. one wedge was welded to the chassis while the other had the thick end capped off with sheet steel and a captive nut welded to the inside of it. This second one was then threaded up the brake rod into a suitable position so as to provide enough tension in the spring to ensure the brakes are pulled off, you can see a lock-nut acts against the captive one and holds it in place. I'm really happy with how this turned out, it looks tidy and works perfectly.

Return springs were a problem well solved

Another pleasant little task was the fitting of the number plate. I had picked up a swish stainless steel back-plate and some rather tidy LED lights from Ebay (£20 the lot, bargain). popping them on took no time at all and made the trailer look way more finished.

Next up was the rear light clusters, As I have mention before we needed to modify them slightly to make them detachable, and compatible with the loom I had purchased. The first job was to fix in the bolt that would pass through the ally bar that the ramps will hook over, a simple matter of drilling a hole in the bottom of them and pushing a bolt through the hole with a lock-nut on the opposite side, said bolt then passes through the bar and wing nut hold the light cluster in place.
To attach them to the loom was a little more involved a this required buying some water-proof DIY multi-plugs, and wiring our own piece of 7 core cable from the lamps and creating a water tight hole for it to pass through then chopping off the existing loom plugs and replacing them with our own. we also had to lay extra wires to account for the fact that the lamps have fog and reverse on both sides whereas most trailers only have a  have a fog on the driver's and no reverse what-so-ever

And there you go, all that remains now is make some provision the attach the spare wheel and get the welder  converted to ally so I can attack the ramps. I'm more than a little nervous about this as not only did all that aluminium for the ramps cost me about £200 but I've never welded ally before and if they fail its going to total whatever is driving up them at the time. No guts, no glory.