Broken Stiffening rod on drawbar Big problem ?

Submitted: Tuesday, Oct 11, 2011 at 03:34
ThreadID: 127671 Views:2213 Replies:9 FollowUps:10
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As you can see from the photo, it has just snapped clean through.

Is it strong enough if you weld it or should you cut it off and replace the entire length ?

I have just come back from a bit of gold detecting at Mt Browne and noticed it when I was inspecting my broken handbrake cable.

Thanks a lot,

Willie.

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Reply By: Bobrovin - Tuesday, Oct 11, 2011 at 04:39

Tuesday, Oct 11, 2011 at 04:39
Hi Willie
Your other post explains why this happened. If you are going to keep carrying your bike around you will need to cut the bar off both sides and replace with heavier flat bar. Welding is definitely not an option
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Follow Up By: Willie - Tuesday, Oct 11, 2011 at 05:34

Tuesday, Oct 11, 2011 at 05:34
The bike has not been carried on the rack yet.
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Reply By: Flavs - Tuesday, Oct 11, 2011 at 06:24

Tuesday, Oct 11, 2011 at 06:24
Hi Willie,
I have seen a number of BT's with that problem.
They replace it with a flat 10mm x 40mm (I think) CHECK with Absolute Trailer Solutions (a sponsor on the right hand side of the forum page).

I presume you were with Mark & the bad weather at Mt Browne? Hope you did ok!

Regards
Noel
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Follow Up By: Noosa Fox - Tuesday, Oct 11, 2011 at 17:29

Tuesday, Oct 11, 2011 at 17:29
We found one broken several years ago and it was welded and then had a piece of 25mm angle welded along side it. Has held no problem.

While at the Muster it broke in another place and was welded with a similar size rod underneath. That is now showing signs of cracking again.

At the Tepon Park Muster there were about 6 vans with broken bars and most were replaced by a local business with the heavier flat bar that Noel said about above.

You are definitely not the 1 in 1000 to have had this happen.

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Follow Up By: Willie - Tuesday, Oct 11, 2011 at 17:35

Tuesday, Oct 11, 2011 at 17:35
Thanks Noel, I will contact ATS and seek their advice.

Yes, I was with Mark at Mt Browne and the wind was a shocker. We heard a weather station to the south of us, recorded gusts to 96km/hr.

I ended up with 65 little nuggets for the massive weight of 7.5gm and had a great time. I am off the Golden Triangle for a week soon - the targets should be a bit bigger there.

Cheers,

Willie.
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Follow Up By: Willie - Wednesday, Oct 12, 2011 at 04:31

Wednesday, Oct 12, 2011 at 04:31
Noel and Brian,

Is the 10mm x 40mm flat steel welded directly to the bottom of the drawer bar (welded all the way along), or is it welded to the same "droppers" as the round rod was welded to ?

I guess this welding will bugger the gal. finish.

Thanks a lot,

Mike
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Reply By: Tracks n About - Tuesday, Oct 11, 2011 at 19:15

Tuesday, Oct 11, 2011 at 19:15
G'Day Willie,
My bars snapped three times before I bit the bullet and replaced them with the flat bar. After one broke,I had it repaired and reinforced. When the second one went I did the same,but then when the first one went again reinforcing and all that was enough for me. Was told that it was caused by everything from overloading, travelling too fast over corrigations to having the airbags too ridged. The only one I believed it may have been was the airbags. ( Naturally I was the 1 in a 1000 ) Personally I believe that the flat bar should be standard on all BTs. Have been told that doesn't happen because of the extra weight. I can think of a couple of other areas where weight could be saved without affecting the units capability.
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Follow Up By: Willie - Tuesday, Oct 11, 2011 at 20:58

Tuesday, Oct 11, 2011 at 20:58
Thanks a lot for your info. I will not get it repaired, but will replace it as you suggest.
Willie.
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Reply By: Noosa Fox - Tuesday, Oct 11, 2011 at 21:11

Tuesday, Oct 11, 2011 at 21:11
Willie,

Was the hand brake cable broken where it goes over the chain link welded to chassie?
If so I have found that the bouncing of the cable while travelling causes the cable to fray and also because the cable is stronger than the chain link the cable wears a grove in the chain link.

I fixed ours by putting a piece of plastic tubing through the loop and securing it with cable ties and then feeding the cable through the tube.
It just stops the cable bouncing and does not affect the use of the hand brake at all.

I have noticed that BTi fix on later model vans is to make the chain link a lot larger, but it will not stop the wear from bouncing.

Brian
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Follow Up By: Willie - Thursday, Oct 20, 2011 at 22:54

Thursday, Oct 20, 2011 at 22:54
G'day Brian,

I just rolled up the cable and cable-tied it out of harms way. Yes, it was broken just where you said and the other side is worn there too. I will get them to put tubing on when they replace it - good idea - thanks a lot.

Willie
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Reply By: Frank Aus - Wednesday, Oct 12, 2011 at 05:55

Wednesday, Oct 12, 2011 at 05:55
Hi Willie, I have had to replace mine and when i was getting it replaced we found that the chassis was cracked, the main cros member was only 1.6mm rhs instead of 3 mm, so i had a new aframe and cross member fitted, cost a packet, also bought a postie for gold detecting and it is great. but i have to put mine of the ftruck rather than the van, due to weight restrictions.
Frank
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Follow Up By: Willie - Wednesday, Oct 12, 2011 at 08:15

Wednesday, Oct 12, 2011 at 08:15
G'day Frank,
Hope my chassis is not cracked. What state do you detect in ? (don't say drugged !)
Thanks,
Willie
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Reply By: Frank Aus - Thursday, Oct 13, 2011 at 06:08

Thursday, Oct 13, 2011 at 06:08
Willie, so far i have been to Halls Creek in WA and the golden triangle in Vic, I have far better luck on the sapphire fields and am in the process of finding a claim, but i am not giving up at all. But i enjoy the hunt as it were, which is just as well :)
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Reply By: Gone Bush - Friday, Oct 14, 2011 at 04:07

Friday, Oct 14, 2011 at 04:07
Willie,

when you have any welding done to the drawbar make sure that the welder knows that the wiring cables run internally down one side of the chassis (RHS on mine).

Ask him what he would do to prevent the heat damaging the cables.

I'm not a welder's bootlace but maybe filling the drawbar with water may be an idea.

cheers

Stephen
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Follow Up By: Willie - Friday, Oct 14, 2011 at 04:56

Friday, Oct 14, 2011 at 04:56
Thanks Stephen,
The break is on the port side - if the wiring goes down the other side like yours, will it still get fried ?
Thanks a lot ,
Willie.

PS I contacted the only caravan repairer in Sydney today, Barnes Caravans. They are so inundated with work they will not take a booking until I ring them in December.
What a joke and what a good opening for a clever fellow wanting to start a business.
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Reply By: Trailer Trash - Friday, Oct 14, 2011 at 05:52

Friday, Oct 14, 2011 at 05:52
Hi Willie
Ring Karl at G & L Caravans at 10 Cann st Guildford Sydney on 96321687.Iwork a couple of doors away & they have worked on several bt's.They do good work & i know they do good welding.Mention my name.
Regards Graham Smith
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Follow Up By: Willie - Friday, Oct 14, 2011 at 08:50

Friday, Oct 14, 2011 at 08:50
OK,thanks very much for the info Graham. I will ring them tomorrow.
Willie.
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Follow Up By: Noosa Fox - Saturday, Oct 15, 2011 at 07:26

Saturday, Oct 15, 2011 at 07:26
Willie,

I had a look at a van that had his bars changed to the flats last year and after the round rods were cut off the flats were welded to the original support legs.

With the wiring, If you disconnect the plugs at the front and then connect something to the end of the cables, you can pull all the cables back towards the wheels out of harms way and then when the welding job is complete on the off side you will have something inside there to pull the cables back through to reconnect.

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Reply By: Noosa Fox - Friday, Oct 28, 2011 at 18:53

Friday, Oct 28, 2011 at 18:53
We have recently had another bar break and while talking with a local welder it has been suggested that instead of repairing or replacing the chine bar that we cut off the chine bars and replace them with some 50 by 50mm square tube so as to form a laminated A frame that would make it a lot stronger than the original with chine bar.

Has anyone had some experience with this or comments?

Brian
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