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Comment by Bill Shockley on January 20, 2015 at 2:43am

The gas tank comes out easily,,,

http://advrider.com/forums/showthread.php?t=847293&page=22

I know mine very well, 33 gallons.

   b

Comment by david craft on January 20, 2015 at 1:23am

Alas...if only I could use 7018 more often. Its a little more prone to arc blow which is tricky on the out of position stuff. Plus, when I did jobs like the one i describe, I usually bend the rod to get a better rod angle. The iron powder flux rods dont like that much. You can sure get a pretty weld though.

Comment by Rich Thomas on January 19, 2015 at 11:57pm

Amen on the stick weld, I like 7018 with a DC welder. The extensions on my coach are attached with three what looks like 3/4 bolts, that's it. I would have to think twice before I tried to pull a fly off a gut wagon with what I have. As far as the torque arm effect and added weight I plan on empty tanks and light loads in the coach its self, it's just me and my little co pilot and we travel light. Bill left a good resource for metals and supplies ( THANKS BILL). I like my M.I.G. as well but air movement blows the argon off and I hate flux core.   

Comment by david craft on January 19, 2015 at 11:20pm

Box tube is almost always better...i did this project long ago...like 20 years...before box was "in". Also, with angles and c, I'm working with thicker steel and thats handy for "out of position", arc welding where you worry about blowing a hole in .120 wall. Anything over .120 would be overkill in box. Like next to the tank, I can get a weld on that angle that may be just too hard to do with tube. The angles also butt right together at the c where I would have to box the end for strength on tube. But your right, box is stonger and much better looking.

Comment by david craft on January 19, 2015 at 10:53pm

I used 6011 dc reverse. I like stick..penetrates the crud and i get places you cant get with wire. The hard part is the welding next to the gas tank. When you get a little arc blow to the tank it softens your stool a little. I laid a 1 1/2" x1/4" x 12" plate on the sheet steel chassis between the tank and spring to distribute the load. Then I cut the angle to match the plate and the c channel. The box is strong at the bumper mounts and spring hanger area. The c channel goes there. The mfg never supports this extension..I think the walls carried it. When I started the project, you actually walked uphill to the extension and then downhill to the back of the coach.

Comment by Bill Shockley on January 19, 2015 at 10:38pm

Sounds like a plan but the motorcycle has leverage so the weight is much more than static plus it has the momentum of suspension movement. I've worked with this stuff:

Strong for it's weight...short side up.

http://www.speedymetals.com/s-202-rectangular-tube.aspx

    bill

Comment by Rich Thomas on January 19, 2015 at 8:50pm

I'll tell you Bill, we are ALL a little off the bubble here; a little slant here and there never hurt anyone. I'm doing a beef up on my camper tail end this summer so I can load my XR650L on the back. I plan on using 2" square single wall tubing and start tying in-in front of the rear axle and carry it all the way back to the bumper and tie it in there. will basically look like a set of latter bars like you see on monster trucks. I had a good welder check out my design and he said it looked good and I won't be adding a ton of extra weight.Bike ways 345 lbs loaded.  

Comment by Bill Shockley on January 19, 2015 at 12:35pm

Great ideas, I thought I was imagining things when I crawled under to look. Really a mickey mouse type setup Winnie created. It's no wonder all the old boxes sag so badly.

I need a good welder or step up myself, what kind of welding equipment did you use to get in there? Thanks for the tip on jacking it square. I didn't do that when I built on the back and everything is a little off plumb as a result.

Live and learn.

   bill

Comment by david craft on January 19, 2015 at 9:50am

Fish plate the top where frame extension meets chassis too...the forces in this design will want to pull this apart lengthwise...this comes out really strong BTW

Comment by david craft on January 19, 2015 at 9:43am

That sheet steel box is where I butted the c...right against the flange with the weldnuts for the van bumper. Welded it all the way around the edge because it works in tension. I fish plated the contact point on the chassis for more surface area to weld the angles. I had the sides of the motor home supported with camper jacks during the process. Because it had that 70's dodge frontend...It really looked pretty new with new side walls and fresh filon to finish.

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