Awning Rail Replacement

[Tropper2196]

Hi all
I have a Swift Conqueror 645 lux 2004, on returning from Spain in March I damaged the bottom awning rail and the lower panel below. I have now repaired it and very pleased with the result. After removing the rubber trim and retaining screws I used a putty knife to push behind the damaged rail and pulled the rail off, I used a plastic scraper to remove the excess putty. I did the same for the bottom Panel and straightened this out as best I could. Had to repair a small section of 5mm ply behind the panel then screwed a piece of batten behind this to get a straight line. It was straight forward refitting using a good grade caravan adhesive. I fitted the new rail again using a good grade adhesive. Filler was used to smooth out the minor marks to the bottom panel I made a rail opening tool to get the flared part to allow for the bottom skirt to be fitted, the actual tool is so expensive to buy and very easy to make the rail looks as good as the maker did.

 

[emmerson]

Now that is what the original Practical Caravan magazine was about! Well done Tropper.

 

[Raywood]

Well done. Not one I would try.

 

[Tropper2196]

If I had taken it to caravan body shop I would have paid at least £500 I did for around £130 and £110 of that was for the new ally rail.

 

[Dustydog]

Well done Trapper.
Two years on following an awning rail replacement I still haven’t finished the flare for the awning bead. Commercially the simple tool is nearly £70. May I ask how you made yours please.

 

[Tropper2196]

I made it very easy I bought a Precision ground hss bar 8" x 50mmx 2mm used a angle grinder and cut the bar into 45mm wide pieces. Mark two of the bars 7mm from end then put the third in between like a sandwich with middle piece 7mm back making a slot I clamped it together with mole grips then mig welded the sides and one end, I used a cut down old screwdriver and welded that to plate to make a handle. marked the ally put some tape on the top edge insert the tool and lift to desired gap. It works perfectly. Im in Hampshire if your nearby I could do that in mins for you.

 

[Tropper2196]

.probably cost me £8 I will be at my van on Wed ill take some pics of finished work and the opening tool get the metal on ebay 2mm x50mm Precision Ground HSS Tool Steel Flat Bar Rod 8" 20cm Tool Making UK Stock

 

[Hutch]

Dusty Dog maybe you could convince a nice mobile engineer to get one and you could borrow that. Failing that I will come down in an hour with a pair of pliers and a hammer, before we go to the quiz. :evil:

 

[Dustydog]

.probably cost me £8 I will be at my van on Wed ill take some pics of finished work and the opening tool get the metal on ebay 2mm x50mm Precision Ground HSS Tool Steel Flat Bar Rod 8" 20cm Tool Making UK Stock

Many thanks for your comments Trapper.. A photo would really help. A mate of mine is a welder so maybe with the dimensions he could replicate your tool. My biggest concern is levering the rail and causing damage!
I’m in Wiltshire near Cirencester.
Many thanks DD

 

[otherclive]

Well done Trapper.
Two years on following an awning rail replacement I still haven’t finished the flare for the awning bead. Commercially the simple tool is nearly £70. May I ask how you made yours please.

When I had to have a new rear panel last year I went to fit the awning and surprise surprise the rear awning entry slot had not been formed. So when I took the van in for a new axle ( 2018 wasn’t a good year) the dealer just swaged one in very quickly. So why not try a mobile MCEA technician to see if they could do it.

 

[Dustydog]

Well done Trapper.
Two years on following an awning rail replacement I still haven’t finished the flare for the awning bead. Commercially the simple tool is nearly £70. May I ask how you made yours please.

When I had to have a new rear panel last year I went to fit the awning and surprise surprise the rear awning entry slot had not been formed. So when I took the van in for a new axle ( 2018 wasn’t a good year) the dealer just swaged one in very quickly. So why not try a mobile MCEA technician to see if they could do it.

My regular mo lie guy doesn’t have one. Too expensive! I can’t be bothered to take it to a main dealer . Time and cost .

 

[Tropper2196]

Well I have pictures just gotta work out how to put pics on here

 

[Tropper2196]

How do you put pics on here?

 

[Hutch]

Trooper, you have to upload our pictures to someone like Postimage. .
Here is an old posting from "photograhphy,
Hope this works. Click on the bit to enlarge. By the way 600 rather than 400 gives a full screen image.

OC, I use post image , and Chrome, and once I have selected the photo and then "share" i click on the right hand side of the second bit down called "dierect link" which then says copied. Go back to PC post page . Go to the little square thing with the chain link. Punch in 400 then below delete the https , and paste in that bit and then insert. Check preveiw and the photo should appear.

It didnt come through.

 

[Hutch]

 

[Tropper2196]

[img size=480mm W 880mm H]https://sway.office.com/2byGTyUgWZJ9ONP1?ref=Link[/img]

 

[Tropper2196]

I think it worked?

 

[Ashwori]

Hi all
I have a Swift Conqueror 645 lux 2004, on returning from Spain in March I damaged the bottom awning rail and the lower panel below. I have now repaired it and very pleased with the result. After removing the rubber trim and retaining screws I used a putty knife to push behind the damaged rail and pulled the rail off, I used a plastic scraper to remove the excess putty. I did the same for the bottom Panel and straightened this out as best I could. Had to repair a small section of 5mm ply behind the panel then screwed a piece of batten behind this to get a straight line. It was straight forward refitting using a good grade caravan adhesive. I fitted the new rail again using a good grade adhesive. Filler was used to smooth out the minor marks to the bottom panel I made a rail opening tool to get the flared part to allow for the bottom skirt to be fitted, the actual tool is so expensive to buy and very easy to make the rail looks as good as the maker did.

Hi
Appreciate it's long shot, but where did you manage to source source awning rail from? I can only find odd meter lengths & they want £50 a meter!!

 

[toad a caravan]

Two images of how I resealed mine..they may be of help