The latest adventure with my '87 Starcraft Nova is to replace the orignal Dexter torflex axle.
The side mount flanges failed on the PO, sending the wheels up into the fenders. The marks/damage to the inner fenders are an indication of how much fun that must have been! The fix out on the road was to gut the brake assemblies and weld the axle beam directly to the camper frame using 2 pieces of angle iron on each side of the axle....welding the angle iron to the axle and to the frame, and melting all the wiring in that area of the left frame channel.
Surprisingly, the axle still functions. In 3 seasons we've had no issues with it, or bad tire wear. But it's the last thing on my list, so it's time to step up and get it done.
It's taken a lot of phone calls to both Starcraft and Dexter. I finally located the specs, the special "Starcraft" mounting plates, and the ball is rolling. Right now it looks like Dexter is going to build to my spec and sell to me directly. Starcraft won't sell directly to anyone any more since Jayco took them over.
Sent all the specs in today and I'm waiting to hear back on a price. Wish I could just send them my axle and have them rebuild it.
That's an adventurous project! You drove for three years with no suspension?
Good luck.
No, the axle still functions just fine.
I'm hoping that with judicious use of a plasma cutter.....or my sawzall.....or both.....I can get the axle extracted without any further trauma to the frame
Ahh... I misunderstood. I see what you're up to now.
(http://www.modmyrv.com/wp-content/gallery/mod-69-image-gallery/shock-absorbers-dexter-axles.jpg)
Now that's funny. I was just getting ready to cut and paste that exact photo!
What's really funny is that the axle still works so good. If you saw how big the welds are, and how much of them there are, you wouldn't believe it. I'm guessing that the rubber cords may have melted initially, but then just rehardened as the steel cooled.
Just got the quote from Dexter. $180.23 and it'll take 1-2 weeks to make it.
Have you considered a used part from a place like
colawrvsalvage.com/ (//%22http://www.colawrvsalvage.com/%22)
or
WKS (//%22http://www.telusplanet.net/public/wks/%22)
just another option ;)
Good luck
No, I'm not up for used parts like this, because they're too inexpensive to purchase new, it's going to be too much work not to do it right the first time, and axle is just too critical of a component.
Not trying to dog you, it's just that there's a place and time for used parts, and this isn't one of them IMO.
One week after placing the order....
I received a call from Dexter this morning. The axle is done, and they were getting ready to ship it out. Should have it towards the end of next week.
Good luck! Hope they made it properly for you.
Yeah, nothing like ordering something that's obsolete, hasn't actually been made in 22 years, and doing it over the phone via word of mouth! But I think my research and there produced the correct specs. so it should be fine. Now if FedEx Ground can just get it here without turning it into a pretzel.
Started the day yesterday with a call from a nice lady at FedEx Freight, "Hi, this is FedEx Freight calling to let you know we'll be delivering an axle from Dexter Axle this morning and it's freight collect, so you'll need to pay the driver.......$750:yikes: with cash or check."
WHAT!!!!!!!??????
After I climbed back down from the ceiling, I explained that it was supposed to have been shipped FedEx Ground for $50-$60, not FedEx Freight.
A couple phone calls with Dexter Axle later, and problem solved. Dexter either ate the entire shipping charge, or they worked it out with FedEx so that there was no charge to them at all, or something, because I got a call back saying the shipping was free, sorry for the mix-up.
I offered to pay them the $60 (I did a rate calc on the fedex site) that it would have been, but they won't let me pay.
So, here it is:
(http://i187.photobucket.com/albums/x242/austinado16/Starcraftnewalxe.jpg)
That's a nice looking axle there. I am not familiar with this type of setup, so the axle tube bolts straight to the frame and the swing arms flex with the load? There are no leaf springs with your setup correct? If that is the case then it prob would be a smoother ride.
Correct. Hidden by the wooden blocks are big metal plates that bolt to the side of the camper frame. The axle tube is held about an inch below the frame........and then yes, the "swing arms" flex independantly. The arms have a square shaft going into the square axle tube, and 4 long rubber fingers trap the square shaft inside the tube. So as the swing arm moves up and down over bumps, it's square shaft is pushing against those fingers.
It is a very smooth ride for the camper though.
I'll post photos of the project.
Man is this turning into a lot of work. "They" welded the axle to the frame, and then welded a piece of angle iron to the front and rear faces of the axle, and then welded that to the frame. There's almost no room for a sawzall blade because on the underside of the camper the floor framework is in the way of the sawzall and in the fenderwell, the trailing arm is in the way.
2-1/2hrs into it, I have one side cut free using a sawzall and an air chisel. There's about a 2" opening torn out of the bottom of the frame so once the axle is completely out, I'll need to weld in bigger section of steel. Fortunately, this is a boxed in section of frame and the axle mounts on 17" 3/4" bolt centers up on the side of the frame.
Time for some lunch, and then round 2.
Only took about an hour to cut free the other side. Learned a bit of a lesson! Again, about a 2" hole torn out of the bottom of the frame.
New axle fit perfectly and I mounted it with grade 8 bolts, washers and nylock nuts.
The camper sits about 3" higher than it did before! I took note of how much the old axle's trailing arms dropped with the wheels removed. The trailing arms are almost horizontal. The spec for the arms according to Dexter's records is 22.5 degree drop, so that's how I had the new axle built. I'm not sure I like the new height, but the axle will settle some, and there sure is some nice suspension travel now.
Here's a shot of the axle's compared.
(http://i187.photobucket.com/albums/x242/austinado16/Axlecomparison.jpg)
Here's one of the new fender height. Prior to this, the bottom of the fender was only about 1" above the wheel.
(http://i187.photobucket.com/albums/x242/austinado16/Axlenewfenderheight.jpg)
Here's how the camper used to sit.
(http://i187.photobucket.com/albums/x242/austinado16/Campsiteatdesertlakereflection1.jpg)
Man that PU is turning out to be quite a "love story".
I am shocked and amazed at the price of the new axle. I would have thought at least twice that amount.
I think that you have more $ in that than I do in my TrailManor. I know that you have a LOT more labor in it.
Nice job....congratulations....:sombraro:
Nice Job Austin!
Is Dexter the only company making torsion axles in campers? Can't beat that price. Glad the shipping price was sorted out for you.
Quote from: wavery;210761Man that PU is turning out to be quite a "love story".
I am shocked and amazed at the price of the new axle. I would have thought at least twice that amount.
I think that you have more $ in that than I do in my TrailManor. I know that you have a LOT more labor in it.
Nice job....congratulations....:sombraro:
To know me is to know that I love "saving" stuff, and I love restoring things and then using them.
I think with the purchase of the axle, I'm at about a grand now, maybe $1,200 at the most. While a do have a bunch of time invested, the camper has never needed any major components, other than the axle and the brake assemblies. So $130 for the brakes, and now the $180 for the axle.
Quote from: austinado16;210774To know me is to know that I love "saving" stuff, and I love restoring things and then using them.
I think with the purchase of the axle, I'm at about a grand now, maybe $1,200 at the most. While a do have a bunch of time invested, the camper has never needed any major components, other than the axle and the brake assemblies. So $130 for the brakes, and now the $180 for the axle.
That's pretty good. I just seem to remember you putting a lot of work into that trailer. I guess that it was mostly labor. If the labor is "Hobby" related (which it seems it must be) that's great. I know the feeling. I used to build race cars and dune buggies when I was young.........the hours that I spent in the garage..:eyecrazy:......no wonder my 1st wife divorced me....:p,
Hey....when are you coming camping with us? (or are you too busy in the garage? :p). We'll be in your neck of the woods next week. We'll be at the Morro Bay CG Oct 4,5 leaving on the 6th. Then we're heading up Hwy1 to Carmel for a couple days, then back down 101.
Yep, this one was sort of thrashed/dirty on the outside, but the inside was very nice. Just the roof front panel and some of the front sides rotted out, and then that right front box corner rotted out. So, yeah, I have logged some hours, but parts wise, it's been pretty cheap. I got the original stove and dinette table for free when I picked up that rotted out Stracraft that I turned into a utility trailer. The OEM furnace was cheap on ebay, as was the Wave 6 Catalytic ($40 on CL). The decal refreshing was pretty cheap. Paid $100 for the OE awning via some horse trading.
Plus, I've sort of spaced things out over the last 3 seasons.
I wish we could catch up to you guys camping. Seems like when you come up this way, it's gymnastics season (just got back from a meet tonight) and we have a meet this coming weekend too. Would like to meet you and see your TM......those things are cavernous inside!! You tow that with a Kia Sophia right;) I now tow my Starcraft with my Rabbit P/u.:D
(inside joke)
Quote from: austinado16;210906Yep, this one was sort of thrashed/dirty on the outside, but the inside was very nice. Just the roof front panel and some of the front sides rotted out, and then that right front box corner rotted out. So, yeah, I have logged some hours, but parts wise, it's been pretty cheap. I got the original stove and dinette table for free when I picked up that rotted out Stracraft that I turned into a utility trailer. The OEM furnace was cheap on ebay, as was the Wave 6 Catalytic ($40 on CL). The decal refreshing was pretty cheap. Paid $100 for the OE awning via some horse trading.
Plus, I've sort of spaced things out over the last 3 seasons.
I wish we could catch up to you guys camping. Seems like when you come up this way, it's gymnastics season (just got back from a meet tonight) and we have a meet this coming weekend too. Would like to meet you and see your TM......those things are cavernous inside!! You tow that with a Kia Sophia right;) I now tow my Starcraft with my Rabbit P/u.:D
(inside joke)
A friend & his family have an identical looking Starcraft, brown in coloring and looks to be the same size ... don't know the year but it goes back into the 80's. They bought it from an estate sale where it had been garage kept and the thing looked new! And got a bargin on it, too!
Here's the only pic I have of it on one of our outings ... that's my little 1706 Starcraft on the left and the their's is all the way to the right ~

Fly
You have to put the (//taginfrontofyourphoto'surl.Andthenafterthephoto'surl,youputthe) tag.
(http://i5.photobucket.com/albums/y155/otcpix/za%20Standing%20Indian%202005/Elisasnewabode.jpg)
That one on the right might be one of the lightweight models, like the "Venture" line. They were white, but usually had the tan canvas with white vinyl over the bunks. Spare tire was exposed with just a vinyl cover, as was the propane tank. That "circus tent" type of awning is about 1983/84 from what I've seen in brochures. Nice little campers and uber lightweight. The brochures show them being towed by a 4cyl sedan of the era.
Thanks for the pic help! ~
But I don't think a four banger would haul his camper ... it's a 12' box! Just don't remember the specifs (or the year!), just that when I looked at yours it looked the same. For sure the tan canvas, seems to me the sides were painted tan (looked like yours!) as best I can remember and don't remember the spare and L/P tank covers.
P/S: Your wheel weels looked the same, too! My friend had a slow leak in his curb side tire and we had a bear of a time getting the wheel off and the spare tire on. Had to deflate the tire in order for it to fit into the wheel well. And it was a 13" tire and wheel! Leads to me to believe ssomeone had made some "modifications" somewhere along the line!
Mmm......wonder what it was then? I blew that photo up 400% using internet explorer and it IS a big camper isn't it! Wish I knew more about the models and all I have is a brochure from '87. It shows the "Starstream" as being the longest model, at 15'-10" closed (bumper to tongue) as compared to the Constellation/Galaxy/Nova bodies, which were 15' even. The Starstream didn't get the plastic aerodynamic nose and tail panels or the plastic tire and propane tank covers, it was a body shape like your camper.
But that brown/white awning that has the side panels, and peak roof, along with the white (at least it looks white in the photos) bunk roof and bunk end vinyl, make your buddy's look like something maybe pre-85? Maybe it was a big Constellation....they were really big back in the early 80's from what I've seen.
I've got a new left brake drum coming and it'll be here in the morning. When I put the new brake assemblies on, I saw that the left drum was really torn up where the magnet rubs, and had a big trough gouged out where the brake shoes make contact. Figured I better grab a new drum for that side since I'm doing all this work. Probably being stupid not to replace the other drum, since everything else is brand new. Depending on how much this drum runs, I may do it.
A new Dexter brake drum arrived today. Came with bearings, races installed, grease seal, and because it's a wheel stud mount version, 4 lugnuts and a new grease cap. $70 including tax.
Quote from: austinado16;211044A new Dexter brake drum arrived today. Came with bearings, races installed, grease seal, and because it's a wheel stud mount version, 4 lugnuts and a new grease cap. $70 including tax.
Now aren't you sorry you didn't order 2.......:p
Yep. Although I may just pound the studs out of the drum and drill/tap the holes to fit the original lug bolts.
Oh good grief....what am I saying?
Update:
The new drum is on and I ordered another new drum for the other side. Once I saw how far out I'd had to adjust the brake shoes in order to reach the old drum...as compared to the small amount of adjustment that was needed on the new drum, I knew it was stupid not to replace both drums. The new one should be here in the morning.
Was keeping quiet over here on the Right Coast as I had heard something to that effect awhile back. Seems I broke a leaf spring on the pup way back when it was on the new side ... turns out Dexter replaced BOTH springs, the one that broke and on the oposite side as well. For all practical purposes, they said (as did Starcraft), that anytime you replace a segment of a running gear on one side you should do likewise on the opposite side.
Maybe it's because the opposite side will feel slighted and give you much grief later on ... I duno ...
Fly
Okay....all back together with new drums, grease, bearings, and seals. New brake assemblies and of course, the new axle.
Just got back from a test drive. The brakes work much better. I can actually feel them now if I just enage them on their own. The camper has a nice smooth ride. Much better than before. Another plus: because the frame is not longer sitting directly on the axle and is now held on 17" bolt centers up on it's side area, the door seems to fit better as the frame is no longer bowing over the alxe.
Total outlay:
Axle: ....................... $180
Brake assemblies: ....... $130
Drums/bear'gs, etc: .... $140
Total..........................$450
Now I can definately say I've broken the thousand dollar mark in rescuing this camper. But I'm still a couple grand in the black vs. buying one this nice used, I've had fun not only learning and doing all the work, but in building it the way I want.
Glad to hear it worked out for you. Your research paid off. That's cheap insurance and should make a big difference with towing you vehicle.