Lift System PUP Viking/Coachmen, What a pain in the pully!

So far I've spent two days working on fixing the lift system on my PUP. I had a cable fray and the top wouldn't go down at the Lakeview trip. I had to cut the cable, but luckily the string I tied to the cable stayed on and I was able to re-thread it through all the pulllies. Still, I've had to remove several cabinets, and parts of others. The tight spaces are hard on a big guy. Still, It's standing on it's own support. I haven't gone down and back up yet. Still putting it all back together. I wound up breaking another cable trying to lift it to fix the one I broke. Both on the front of the PUP, furtherest from the winch.

I used the 3/32 aircraft cable on the shorter run of the two and went up to 3MM cable on the longer run. I temporarily spliced the new cable to the old and then pulled them through. Whoever designed this lift system certainly was creative. All that was tedious, but wasn't the real problem. The real problem was the first pully beyond the winch. It is welded to a part of the channel for the lift arm push assembly, and was horribly bent. By the looks of the gouge in the metal, it has been bent for quite a while. This may have been why it was so hard to crank before I put in the electric winch. Getting that piece out was a true chore. Getting it straightened out and functioning again was an even bigger chore.

The good news is that it seems to be almost done, and I discovered some vacant space that a slight modification to the cabinet wall will open up for me. It will mean aobut three cubic feet of extra storage total between the two cabinets. I also now know a whole lot about just how this lift system works.

I've got to get this contraption ship shape before the River Plantation trip.

Was wondering why I hadn't seen any new redneck camping jokes lately Better getting working, times a running out for the RP trip.

Coolbreeze1

I'll take some pictures of the cabinet mod when I'm done. It's not pretty and perfect, but it does add quite a bit of space. I'm waiting on the glue to dry on some of the parts, so I can put it all back in.

Wow, I was just about to ask if you have any pictures and then you post this. I guess that I will get to see your handy work at RP

Coolbreeze1

http://www.flickr.com/photos/29891611@N03/...57622244947660/

That's the link to the pix of my mods. Kralcamper, you'll like these, especially the outside shelf.

You've been very busy with all these mods. Will be looking to see them in person at RP

Coolbreeze1

I can see how little Jon will fit in that porta potty room, but Richard, you'll never fit your a big man

Coolbreeze1

[QUOTE]

Don't say it Richard, Don't say it Richard, Don't say it Richard.

[QUOTE]I can see how little Jon will fit in that porta potty room, but Richard, you'll never fit your a big man

Hey!? I resemble that remark!! lol

The remark is pretty accurate for me, but hey, if you got it, roll with it! I've got about a hundred extra pounds of it. Well, maybe only 90 extra now. But still too many.

I've got to take pix of my setup for repairs. I finally put the top up today. My wife helped me. This made it considerablyharder, but I just kept running out of hands trying to do it myself. I used a strong ladder and a 2x4 to lever up the top in stages.

It's up, but it's not pretty. There's more damage than I thought. Tears in the canvas, etc. I've got three lift arms that will need repair, one of them may have to be replaced. To keep it from falling, I have my pre-cut boards you are all familiar with, plus 2x4's at an angle wedged between the top and the ground. Additionally, I have ratchet straps running from the top to trees and stakes in the ground. I'm taking no chances after having it fall TWICE! on one trip. The kids aren't allowed within 10 feet of it at this point.

My plan is to start taking out the cabinets tomorrow, again! and re-do the lift system. I suspect that the slightly larger cable I used for the longest run must have gotten stuck in some tight passage, oh what a joy finding and unsticking that will be.

There is good news though. I finally decided to try my bizarre theory on fixing the front door that kept getting wider. I leveled everything out, then raised the front another two and a half inches or so. I extended the front stabalizer to the ground, and then put the jack back down. Then I stood in the doorway and jumped. The doorway narrowed at the top just a bit. I did it again and again until the door frame is sitting nice and straight now. Lesson learned, these things really are made of kleenex and spit, instead of steel and wood.

I'll post what I learn when I get the cabinets opened up and taken apart.

Rain, rain and more rain. It's supposed to be nice tomorrow. Perhaps I can get the cabinets out then. I'm getting prepared for quite a mess of broken and jammed up cables.

Richard,

Just take it one small step at a time. Take your time. It might take a little persistence but, in the long run it will go back together smoothly.

If you need any assistance, please PM me and I'll do whatever I can.

remember, when you get to the 1st main bracket in the back (opposite from the winch), if there is any movement in that bracket, use whatever you can to re-enforce it on the forward (meaning toward the front of the camper)side of the bracket and, if possible, make connections to the frame. replace any bent or warped pulleys.....You probably already know these things, but I just wanted to remind you of them so you'll have a reference point.

Good luck
I know you can do it!

Dave

Thanks Dave. I'm really thinking I made things much worse with the slightly larger cable to the furtherest lift arm. I suspect it's all jammed up, and that caused the others to be overloaded, and the main cable broke. I've yet to bring myself to take the first pannel out, but I will. I have to do it, or start using the tent again. I'm too far along to give up. I'm just hoping I don't have to track down parts from Viking.

It is possible that the larger cables have caused the problems. There is not much room on the pulleys for cables. I had originally thought about that myself (because they all "should" travel through the pulleys at the same rate) but decided to go with correct size.

With your winch being fairly new, I'm surprised that your main cable was one that snapped. I'm assuming that when you say "main" cable , that you mean the one that wraps around the winch itself. Mine is approx 1/4" cable on the winch. I would think that any others would go before that one, or at least that the eye bolts connecting to the other 4 cables or the cable ends themselves would open up first.

Tracking down parts was easy. Viking/Coleman was very helpful with a parts list and diagrams but, they would not sell to me direct, I had to go through Bob Cox, a Viking dealer in Knoxville. I just don't like working with dealers very much. Although Cathy's was very good to work with before they had to close up shop.

I would like to see pics of whatever you find when you open things up.

I highly recommend getting the safety bars along with any parts needed for your camper.

Dave