Seriously-Pulley and cable replacement

[Bluedog225]

Ok.  I'm pretty handy (very handy).  I can even fabricate some basic parts on site.  

I don't look forward to it but I am fine with replacing the lift components on my 1974 Coleman Brandywine.  Nothing is broken but close inspection reveals that the pulleys are old/worn/chipped/sagging (I can sympathize).

I plan on putting about $2000 (min) into the trailer for new canvas, electric, water, flooring, brakes, roof repair, etc.  At the end of the day, it will be a pretty nice rig.  Very light, no major deficits, customized.  I prefer the old to the new due to the solid plywood, heavier construction, sheet metal (light) cabinets, etc.   And, like the Charlie Brown Christmas tree, it needs me...

I don't want put all this work into a pop up that doesn't have a repairable lift system.

But I can find no source of cable/pulley replacement parts on the web.  None.

Am I going to have to fabricate a whole new system?  I know (from sailing) that I can have the cables fabricated and I can probably piece together pulleys and parts but some of the specialized pieces are going to be next to impossible to match.

Is it time to throw in the towel and just drop $3000-$5000 on a late model fixer upper?  Or go with a hard side casita/scamp/boler?

Does anyone know where I can get parts and pieces?  I really don't want to go any further without some reasonable belief that I can finish and do it right.

Thanks

Tom

[flyfisherman]

Maybe this outfit might have some answers for you. In the past there have been some posts saying these folks had helped them with lift system parts and problems.

http://www.customcylindersintinc.com/camper_trailer_roof_lift_system.htm



Fly

[Old Starcraft]

Tom,
 
Speaking from experience on my 76' StarCraft the Cable system is a higher aggrevation, but less of a cost factor as long as you can get the replacement parts needed. I purchased replacement cables cut to exact length, and with the fittings on the ends, from the factory for $126, but have read others that have purchased cable from Lowe's, cut to length, and crimped for under $50. I know working with StarCarft, well before the buy out, most all parts are still available from StarCraft. I would hope Coleman would be too. Try to find a reputable RV dealership with experienced staff and I'm sure they can help. I would also try the resource given by Fly as well as others. I have one dealership that has a generic website, but has a tons of parts peices in stock. Even a section for pup parts. I'm not big on promoting one over the other but can't help it when you come into a place with an odd / old part and they almost rather guess what it is then have you tell them, they're really into what they do. For specific questions I'd call them.
 
http://www.tonysrv.com/
 
 
As far as putting money in it I would also look at newer units as with these tough economic times I am finding more and more cheaper pups listed on places like Craig's list.
 
Good luck with your Pup, nothing gives more satisfaction than restoring something and having it look and work great !!! Keep us posted too.

[ScouterMom]

I have a 1973 starcraft - and prior to that, a smaller 1976 - despite their age, I stuck with starcraft because they tend to use common parts and my previous experience with Starcraft was that their people are the definition of 'customer service' - doen't matter how old your camper is or how many owners it's known.

However, I am extremely budget minded (read that as 'cheap').

Like Old Starcraft above, I purchased the custom parts (cable & pulleys) directly from starcraft to replace the lift system on my first camper.

But when I got to the 2nd, I kinda knew more what I was doing, and chose to make my own cables -If I remember right, ALL the cable and crimps, etc for the main cable and the 4 posts cost me under $30.  The pulleys are tougher.  you can FIND pulleys - the trick is to duplicate how they mount to the lift arms.

I took to carrying a pulley piece around with me to compare sizes and show anyone who knew hardware. I also took some close up photos of the pulleys, wheels, and other parts I needed, and posted them on my photo site - networking with a photo helped me find stuff I never would have found by verbal description!

I had gotten to the point where i was going to buy the pulleys I needed from starcraft again, when I found appropriate sized (Brass)pulley wheels at my own local ACE hardware, and I had figured out how to drill out the rivet holding them on and how to re-use the old mount.  In the end, I think I had to actually replace ONE pulley.  Most were bent, gunked up, (threads of steel cable trapped between pulley and frame) and were reparable.  The ones that had bent frames to the pully mount, I cleaned, straightened, and moved to less stressful posistions in the camper.

I found two things you should look for in your lift system -

Originally, many 70's campers used plastic pulley wheels (my '76 had these) they wore on the edges and allowed the cvable to drop out of the groove and bind up, eventually tearing or cutting the cable - or just plain getting stuck.  The replacements starcraft sent me were steel wheels. so look for METAL wheels on your pulleys.

Second, most of my 'pulley' issues were not really with the pulley wheels themselves - my '73 is a much larger camper and heavier roof - so while it's older, it had all metal pulley wheels (either that, or someone else had replaced them with metal ones, which I doubt, as there was no evidence of much maintenance on it, ever.) Mostly I found the lift system got 'bound up' because of gunk collecting on the cables, and them being 'forced' through the system - which caused them to be pulled off the pulleys or scraped against the frame and worn. On my current '76, the cables were literally shredded!  It takes alot to shred steel cable! If someone had just kept the cables cleaned and lubricated every few years, and not FORCED the lift system when it got touchy - it would not have had any problems.

I bet if you tear into your system, you will find that many of the parts are repairable and re-useable.

If not - here is another good source for old camper parts - but I strongly encourage you to post close up, detailed photos of the parts you are looking for - or e-mail them to potential suppliers, as it save ALOT of explaining.  Many campers use the same parts, so you wouldn't have to necessarily find them from a 'coleman' camper or supplier -

Try here -


http://colawrvsalvage.com/usedParts.asp

and here

http://www.telusplanet.net/public/wks/



good luck!

Laura

[wavery]

I hate to be a "stick in the mud" here but putting $2000 in a 35 year-old PU doesn't make a lot of sense to me.

If you need a hobby, that's one thing but if you're goal is to have a low-cost, serviceable camper, I think that you might be able to do better than that.......JMHO

What area do you live in Tom?

Wayne

[Old Starcraft]

Tom,

Now that I'm home I found another source that I found on this site.

http://www.telusplanet.net/public/wks/

Here's a good reference site as well.

http://www.rvworkshop.com/pop_up_camper_parts.html

Good luck on your project !!!!

[brainpause]

I hate to be a "stick in the mud" here but putting $2000 in a 35 year-old PU doesn't make a lot of sense to me.

If you need a hobby, that's one thing but if you're goal is to have a low-cost, serviceable camper, I think that you might be able to do better than that.......JMHO

What area do you live in Tom?

Wayne

I have to side with Wayne.

We finished a 24 year old Starcraft a couple of years ago. Seemed like every time we turned around, we saw something else that needed fixing/replacing/changing on it.

Even a brand new trailer will need maintenance and fixes.

And I did replace most of the cables on mine. Even with exact-fit cables from Starcraft, it was a pain. I would never have gotten the lengths correct if I had to fabricate them.

I suggest getting a late model fixer-upper, or getting a good trailer (used but well-cared for). You will still get to use your manly man tools on it.

Larry

[Bluedog225]

Wayne-that Trailmanor looks nice.  It's everything this Coleman is not...

I'm in Austin, Texas

Jump first; look later.  I know.  I need to throw this one back.....I have about 100 other projects to work on.

This was really just intended to be a place to stay while I build a cabin on some land I own in Smithville (long term project).   And maybe an occasional trip to the coast for sea kayaking.  Part of the appeal was that it was light enough for my Forester.

May be heresy but I'm starting to think I would be better off with a Casita/Scamp/Boler/Burro.  I would avoid the two biggest issues I'm facing (canvas and lift system).  With those rebuilt however, it would be solid little foundation to build on.  I hate the particle board and OSB in the new units.  Just a pet peeve.

Thanks everyone for the good links and thoughts.  The general consensus is that changing cables is a royal pain.  I will probably go ahead and finish the roof rebuild and chew on this for a little while.  Should be pretty straightforward.  Just metal, 3/4 foam, and a cardboard ceiling.  Kool Seal on top, new ceiling on the bottom, and a new 12 volt fan.

Maybe I can find someone on craigslist looking for a little project...

Thanks again.

Tom