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...................................................--- New Front & Mid-Bunk ---
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On this page the front and mid bunks will be made in a different manner than the factory setup. I wanted to get the wood off of the frame and create a metal to metal union on the frame to cut down of rust in that area like what was happening as a result of the wood bunks sitting directly on the trailer cross-members. Note that the new mid-bunk is actually where the factory rear bunk was. On the next page I'll extend the frame and put in a rear cross-member that will support a new third, rear bunk.
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First a new bunk system will be made for the near, 4 arrows, bunk and then a similar one will be made for the mid bunk, top arrow, and latter for the third, rear, bunk.
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The first step was to make plates that would go above the original mounting holes on the cross-member.
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The new plates were separated from the original cross-member with pieces of solid round aluminum cut to length and drilled. Now the aluminum is in contact with the cross-member and that should cut down on rust on the trailer. The upper pieces that will be made next might still rust being in contact with the wood bunks, but they could pretty easily be re-made and replace these.
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Above we can see the two plates mounted to the cross-member on the starboard side of the trailer. This raises the bunks about an inch, but the new axle/sub-frame also influences the boat height off of the ground and it is about the same as before any of these mods.
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Next a length of redwood was cut and laid on top of the plates and I hit it with a hammer and ....
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.... that left the bolt head imprints from the bolts that hold the plates to the cross-member. Next ...
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.... I drilled into the wood a small amount and that left a recess for the bolt head so that the wood bunk sits flat on the plates. To hold the wood to the plates ....
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.... these tabs were made and then ...
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.... bent and then ....
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... welded to the plates.
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Next a piece of strap was cut and tacked between the plates and then ...
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... was final welded to the plates and the tabs were finished welded and ground fairly smooth. The finished pieces were then marked with stamps so that I would know their position on the trailer as MacGregor didn't quite make everything the same on the trailer.
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Here on side is in place. The original bunk angles were preserved, just raised a little and the boat still fits the trailer fine.
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The arrows point to holes in the tabs. Latter the wood was covered with carpet and is held in place with SS screws that go through the holes, arrows, in the tabs and into the wood. They don't do much really just keep the bunks in position. The weight of the boat does the rest.
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The same process was repeated for the mid-bunk, the old aft bunk. When the third and new aft bunk was added, next page, this process was more or less repeated. It is now much easier to replace a bunk as you just back out the 4 screws holding one on. No long bolts that go through the cross-members anymore.