GRACEMUR SUNNY CHASSIS AND COUPLING Rebuild Advice

[sue]

HI I am hoping to get some advice on renewing the tow coupling. I have removed the old one and went to purchase a new caravan coupling but the holes line up half across the old holes. Do I weld the old holes and re drill ? Do i weld a new plate on top off the chassis and attach coupling? Or do I rebuild the chassis .
Also the new couplings are 2000 kg rated is this still ok as i have manually override brakes and vans weight 700 + loaded 300 approx Will this weight still brake on 2000kg coupling or is there a 1000kg coupling available?
Could I also get some advice on the sunliner chassis. Do Sunny owners usually rebuild the chassis and replace the axles ,drums ect or is the design of the old chassis and axle a good strong design? Unfortunately my old van has a small section of rust in one part of the sub frame due to the tyres being flat and that section was sitting in dirt but the rest is Ok mainly surface rust The springs are covered with old grease so they have been preserved but should I replace the bolts due to age ? The van has not been moved for 25 years and I have jacked it up on blocks of the ground. I am waiting for the rain to stop to finish the paint job and it is coming up a treat. All advice will be appreciated as most of you have already completed your vans and they are a credit to you Thanks Sue

[dave]

Hi sue,

With regards to the coupling, have you got enough room to move the new one forward or back enough for a fresh set of holes ?

If not, filling the holes and re-drilling would be the easiest.

Although drilling half-on/half-off a welded hole can be tricky with a hand held drill, as the drill bit will try to wander away from the hard weld metal.

[cruisindoug]

If they are not halfway through the holes you might be able to ease the hole over with a round file - don't get too carried away though you want good coverage. And use a good thick flat washer. You can only do this a SHORT distance (a few mm) otherwise dave's solution is best. Cheers, Doug.

[Jennison]

Hi Sue
Do you need to replace the old one - is it broken and if it ain't broke why replace it?. Someone will remember which thread (probably the tow coupling thread) its on but if your van is made before a certain date it does not have to have a new "rated" coupling.
The thread has the legislative ref point and everything to quote to your rego checker(as most of them seem unaware of this)
jennison
PS I will look for and possibly update this comment

[cobber]

G'day Sue..... and Jeff,

Jennison would not be surprised if I were to ask you the same question Sue.................. why do you need to replace the existing coupling ? (if it is the original one when the 'van was built)

IF.... you wish to keep the 'van original, and the original coupling is in good condition, you do not have to change it.
click on this link and spend the next couple of hours reading it the main point is the blue slip man should not be using the ADR rules.... for our vintage caravans in NSW AIS 24 is what he should use and in Vic. VSI #24 applies to Vintage Caravans.

Of course if you don't keep the 'van original in all respects the ADR (Australian Design Rules) are what you are stuck with.

Cobber.

[sue]

Hi Guys Thanks for your input. Hi Dave no I haven't got the room to move the coupling and drill new holes .I might be able to position my drill press over the chassis to redrill the new holes if filled with weld. Hi cruisindoug unfortunately the holes are 1/2 way across the old holes. Hi Cobber and Jennison, Yes afraid the old coupling is cactus Badly pitted and corroded and seized with a weird tow ball attachment. What about welding a new plate with holes on existing chassis plate?

[Smiley]

G,day, I've welded on a new plate on other vans no problem even giving a bit more length to the draw bar when there too short.
smiley.

[sue]

Thanks Rod, I Will Weld a new plate over existing one Thanks' for the tip on the drill press.

[foss]

Hi Sue
Regarding your question about the 2000kg override coupling. I put one on my Sunny and yes the Sunny was not heavy enough to apply the brakes. I then bought a 1000kg coupling from Camec and that works quite well.
Regards Gary

[sue]

THANKS GARY FOR THE INFO . WILL RING CAMEC ON MONDAY