New Torsion Axle

austinado16 · Sep 10, 2009, 09:37 PM

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.

92_Flagstaff · Sep 10, 2009, 10:31 PM

That's an adventurous project! You drove for three years with no suspension?

Good luck.

austinado16 · Sep 10, 2009, 10:35 PM

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

92_Flagstaff · Sep 10, 2009, 10:48 PM

Ahh... I misunderstood. I see what you're up to now.

austinado16 · Sep 10, 2009, 10:52 PM

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.

austinado16 · Sep 11, 2009, 01:09 PM

Just got the quote from Dexter. $180.23 and it'll take 1-2 weeks to make it.

Recumbentman · Sep 11, 2009, 02:15 PM

Have you considered a used part from a place like
colawrvsalvage.com/
or
WKS
just another option

Good luck

austinado16 · Sep 11, 2009, 02:22 PM

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.

austinado16 · Sep 19, 2009, 03:35 AM

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.

92_Flagstaff · Sep 19, 2009, 06:45 AM

Good luck! Hope they made it properly for you.

austinado16 · Sep 20, 2009, 02:10 AM

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.

austinado16 · Sep 24, 2009, 09:48 AM

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:

JohnandLeann · Sep 25, 2009, 01:26 AM

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.

austinado16 · Sep 25, 2009, 09:51 AM

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.

austinado16 · Sep 25, 2009, 04:01 PM

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.

News:

New Torsion Axle