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Old 09-16-2011, 02:16 PM   #1
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19H bumper mod

Hi All,

Here's some pics of the strengthening I had done to the bumper in order to carry the bike rack. I also did some other stuff like slide the bike rack all the way into the channel and drilled another hole for a regular 5/8 pin, then drilled again for the Thule anti-sway bolt. this way the rack doesn't stick out as far and I can add a locking pin if I want.

Hopefully you can see all the additional surface area my welder added for me. The original owner (yes, I got the 2011 used - short time; long story). Anyway he had welded just the short receiver channel on the bottom and tried to carry 2 adult bikes with it. they got 100 miles and it tore the original bumper brackets wide open out of the bumper.

I had that fixed and worked with my welder to make sure we had enough surface area and tied it into the frame in additional spots. I put a regular drawbar in there with a ball on it and stood on it and bounced up and down...that's 220 lbs bouncing on it and it didn't flex a bit. The welding cost me $90 - I gave him $120 to add a little tip because I think he did such a great job. The Thule rack I just bought today off Craigslist for $60.

…oh ya, add $18.00 for the Milwaukee 5/8’s reduced shank drill bit I needed for the holes in the rack and channel.

I have already tried and I can fold it down with the bikes on it and get it back up and pinned by myself as it will have to go down to open the rear bed. Also, I can see the 2 outside bikes from my onboard rear camera so we'll see how much movement if any there is down the road. It sure feels very solid...there is no movement in the channel with the pin and the bolt in.

Added a few more shots to show more surface area. All bolted on with 9 Grade 5 - 5/16 hardware.

Always open for questions.

Mark Fisk
Attached Thumbnails
BumperPaint.jpg   BikeRack.jpg   Channel2Frame.jpg   Pin&Bolt.jpg   BikesOn1.jpg  

BikesOn2.jpg   Bolt2FrameMiddle.jpg   BoltOriginal1Inside.jpg   BoltOriginalPlus1.jpg  
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Old 09-16-2011, 02:24 PM   #2
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Nice work Extremist. You are becoming a "mod" authority!
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Old 09-16-2011, 02:31 PM   #3
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Nice work Extremist. You are becoming a "mod" authority!
Thanks Crabman - labor of love...You should see my motorcycles!
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Old 09-16-2011, 05:22 PM   #4
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Mark,

Looks like a great mod that should hold up just fine traveling down the road, unlike the prior owners attempt.

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snip.....and pinned by myself as it will have to go down to open the rear bed.....snip
I would make one recommendation, and that's to replace the standard 'bent pin' with a straight one. The bent pins have a tendency to elongate the metal where the inner radius of the pin comes in contact with the metal (happens all the time on TV receivers).



The following pic shows what can happen (mild case):



If you can't find a standard straight pin/clip, you could go with a straight receiver lock like this (they do come in a couple of different diameters): http://www.campingworld.com/shopping...eceivers/56171

Bob
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Old 09-16-2011, 06:12 PM   #5
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Thanks Crabman - labor of love...You should see my motorcycles!
OK, let`s see `em! Pics?
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Old 09-16-2011, 09:32 PM   #6
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Very nice Mod EXTremist! Think I need to find a square bumper for mine now and start the Mods'.
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Old 09-17-2011, 06:24 AM   #7
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Thanks again Bob - I plan to get a straight locking pin...too bad it won't be keyed the same as my TT pin. That is my backup emergency (kids played toss the locking pin game while camping) pin.
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Old 09-17-2011, 06:33 AM   #8
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OK, let`s see `em! Pics?
Oh...poor babies have been totally neglected since I got the TT. I have 4 of them.

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Old 09-17-2011, 07:08 AM   #9
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All,

I did add a ratcheting tiedown to this setup around the Thule up to the drop bed handles to take up the slack in the Thule pivot. I get it that the rack has to drop down but watching it on my rear cam while driving on a notorious hwy (100) here (on purpose) for "road-bucking" the rack just bounced around too much for me.

I will probably add some "soft ties" to those bed handles to avoid damage from the hooks but the strap is a must in my opinion.
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Old 09-17-2011, 07:52 AM   #10
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Mark great job/ engineering, I aasume you converted the "C" bumper into toilet paper, which is all it's good for. Larry
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Old 09-17-2011, 09:23 AM   #11
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Originally Posted by EXTremist View Post
Oh...poor babies have been totally neglected since I got the TT. I have 4 of them........snip
Mark,

I don't have four, but I do have one that keeps me playing in traffic (loaded for a weekend camping trip):



Bob
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Old 09-17-2011, 03:57 PM   #12
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Nice, I like how clean it looks.
I would personally be a little concerned about the fact that both Jayco and the frame manufacturer say "no" to attaching anything to the frame. Maybe it's just a precaution on their side ....
How many bikes at what weight do you think would be ok? Our four bikes come in at 140 lbs total.
I ended up putting a bike rack over the bed of my truck (can still use the bed under the truck for everything else).
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Old 09-18-2011, 06:30 PM   #13
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Nice, I like how clean it looks.
I would personally be a little concerned about the fact that both Jayco and the frame manufacturer say "no" to attaching anything to the frame. Maybe it's just a precaution on their side ....
How many bikes at what weight do you think would be ok? Our four bikes come in at 140 lbs total.
I ended up putting a bike rack over the bed of my truck (can still use the bed under the truck for everything else).
Thanks - I did some testing with the 3 bikes on it and mentioned elsewhere I ran a ratcheting tiedown to the hybrid bed locks to take the slop out of the Thule rack...too much bouncing on the camera.

I did throw a standard drawbar into it and stood on it myself and bounced up and down and didn't see or feel any flex other than the TT axles. I'm 220 lbs so I definitely think it's capable of the bikes or even a tray with my gen on it.

I know Jayco doesn't want anything back there but my welder actually looked the frame construction over real well (he didn't want to do any work that might cause an issue or fail in any way - if anyone is in MN and needs a welder, I highly recommend Bohn Welding in St. Louis Park) and he was impressed with the strength and design of the frame rails for an "ultra-lite" trailer.

After the paint fully cures and I've hauled the bikes a few times I will be looking very closely for any "witness" marks indicating serious flexing etc. In the meantime, the season is almost over and I'm not sure how many more trips I will take with the kids.

Mark
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Old 09-18-2011, 06:32 PM   #14
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Mark,

I don't have four, but I do have one that keeps me playing in traffic (loaded for a weekend camping trip):



Bob
Beautiful Bob! The group of guys I ride long distance with ride mostly full-dress Ultras.
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Old 01-28-2016, 10:03 PM   #15
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awesome i need 4x4 or add on htich i hate those 1 by 4 bumper, need something to carry my generator and storage bin in back one of my friend own welding shop. you buy 4x4 bumper? i wonder where to get or something i have to mod..
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Old 01-28-2016, 11:13 PM   #16
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Welcome to the JOF.

If you don't get some responses, it might be best for you to start a new topic. This thread is rather old.
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Old 01-29-2016, 07:06 AM   #17
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Jayco 23b carrier on rear bumber

I would like to add a carrier for my portable dog pen (less than 100 lbs) to the rear of my 23b hybrid camper. My bumber is bolted to the camper frame. There are additional holes in the frame. Can these holes be used to attach structure to attach the carrier? I was thinking I could attach the bottom of the carrier to the bumber with a bolt on attachment and then add reenforcement attached to these holes. How will this affect my warranty?
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Old 01-29-2016, 08:13 AM   #18
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jaw and cooljayco12:
You may get better response if you start a new thread with your question in lieu of tagging in onto this older thread. If you want to do that ask a mod for help.
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