Another Axle Upgrade Thread

ScottK · 06-14-2020, 08:26 AM

It's been awhile since I've posted and sadly, I'm no longer a Sunline owner. We sold our 3rd Sunline this spring in favor of a new smaller 2020 Forest River camper that would be more maneuverable and easier for long trips. Here it is:

We had an AK trip planned this summer, but have now canceled due to Covid related closures. But it's ok, there is still plenty we can do in the lower 48 this summer. Here's the new rig. It's nice, but boy it sure isn't built like a Sunline. I've already made numerous additions, but the big ones were reinforcing the A-frame and putting a new axle on. My motivation was mainly to increase the safety factor of a single axle and only a 900# cargo capacity. That weight would get eaten up very very quickly. It only had D rated tires, which had to go as well. I also wanted a little more ground clearance. The factory axle only had 10x1-1/2 brakes and I could tell. Coming from campers and my utility trailer that has dual axles, I really noticed the lack of stopping power. We got a great deal on the camper, as we were actually the 2nd owner. I was able to justify the added expense of the upgrades.

ScottK · 06-14-2020, 08:38 AM

I unbolted and cut off the old Lippert torsion 4400lb axle plates, build a 2x2 (1/4 wall) rectangle frame to raise the new axle up. I ordered a 5500lb rated Dexter Torflex axle with Nver adjust brakes and Nver Lube sealed bearings. It arrived in a couple weeks and I put it on. You can see the 2" tubing under the main frame with I'm not very good at taking progress pictures, but I have a few pics of the job. I went about the alignment measurements from the coupler to the axle similar to John and Tod did in their axle replacements. Just another little twist. I used a "convert-a-ball" and a dowel to secure a rigid measuring point. Then I leveled two wheel studs and measurement to the closest bolt on each side. I was only an 1/8" off on my first measurement. Wow, sometimes it's better to be lucky than good.

Not sure why my pictures got rotated in the upload process...

ScottK · 06-14-2020, 08:48 AM

I got larger E-rated AT rated tires in 265/75/16. I admit I'm a sucker for the offroad look and I wanted a big stout wheel again for some safety factor. These were only a bit more than a top quality trailer tire. We do have plans to do that AK trip and also a Newfoundland trip as well. So these tires are about 2-3/4" taller than the factory tires and 1" wider. I calculated this in when I ordered the axle as to have proper clearance in the wheel well and not stick outside the camper wall.

And a few finished pics with the axle and wheels on.

ScottK · 06-14-2020, 09:02 AM

Here are a few of the A-frame reinforcement. I know Sunline had a few models that had A-frame and header issues. This camper used such light materials that I felt I would have issues eventually. I wanted to put more weight up there and again wanted more safety factor. And it just felt springy and weak to me. So I reinforced it by adding 2x2 tubing under the existing A frame. It made a huge difference. Much stiffer now and gives me the confidence she will hold up for long rough trips fully loaded.

ScottK · 06-14-2020, 09:04 AM

Couple more "mostly" finished A-frame pics.

ScottK · 06-14-2020, 09:08 AM

First trip out a couple weeks ago. Boondocking. Just a 2 hour drive to test everything and one overnight with the family. Rock solid now. Tows beautifully, stops WAY better than before, and I love the extra clearance.

Huge thanks to JohnB and Tod for all the detailed descriptions on their axle and frame repair projects. It was a huge help in proceeding confidently with my project and achieving the desired outcome. Thank you!

ScottK · 06-14-2020, 11:55 AM

One more of the finished A-frame

**JohnB** · 06-15-2020, 11:39 PM

Wow!!!

Great work Scott. Thanks for sharing.

OK, I'm going to borrow your convert-a-ball idea for ball coupler alignment. My 2004 T317SR project camper has some serious axle alignment issues that I need to fix when I get onto restoring that camper.

The axle upgrade came out well. Why they downsized to that 4,400# axle tube is beyond me. The cost difference at the OEM level to a 5,200# is not a lot. Keystone and Forest River are doing that on some of their product lines. Sunline would of put a tandem axle under that weight of camper can moved on.

Glad you were able to make it out camping.

John

Tod Osier · 06-16-2020, 05:55 AM

That looks great, I’m sure you are going to like that setup! We are on hold for Alaska too, so I’m sympathetic. I’m hoping something positive will be announced this week, but that is fool’s hope, I think. We had a whole summer trip planned and would have left this week, but are hoping for a border opening in July (not likely).

ScottK · 06-16-2020, 06:42 AM

Quote:

Originally Posted by JohnB

Wow!!!

Great work Scott. Thanks for sharing.

OK, I'm going to borrow your convert-a-ball idea for ball coupler alignment. My 2004 T317SR project camper has some serious axle alignment issues that I need to fix when I get onto restoring that camper.

The axle upgrade came out well. Why they downsized to that 4,400# axle tube is beyond me. The cost difference at the OEM level to a 5,200# is not a lot. Keystone and Forest River are doing that on some of their product lines. Sunline would of put a tandem axle under that weight of camper can moved on.

Glad you were able to make it out camping.

John

Thanks John! I tried Tod's method at first but I didn't have a flat enough lip to clamp to so it wouldn't stay in position solid enough. With this method, the ball could rotate/tilt and the block could slide up or down until it found a nice solid position. Then the clamps held it well. I didn't use a spring tension gauge either and although it would be the most accurate, I felt like I could tension it by feel and get very close. If I had one, I would have used it, however.

ScottK · 06-16-2020, 06:46 AM

Quote:

Originally Posted by Tod Osier

That looks great, I’m sure you are going to like that setup! We are on hold for Alaska too, so I’m sympathetic. I’m hoping something positive will be announced this week, but that is fool’s hope, I think. We had a whole summer trip planned and would have left this week, but are hoping for a border opening in July (not likely).

Thanks Tod. I've been up to Alaska many times and driven it once back in the 90's. Lived there for one winter too. It must feel like winter (except for the cold and dark) up there to them with so few people and big RV's lumbering around. We're not going to even try this year, whenever the border opens back up. It's a trip worth waiting for.