Great Loop: Shake, Rattle and Oops

I have come to the conclusion that trailering a boat is an quick and easy method to expose less than robust design decisions.  It has also reinforced that regular stops should be made each day to fully inspect the boat and trailer.  Today's excitement was finding that the rack which supports our solar panel and "rocket box" tried it's darndest to fly from the top of the boat.

The day was quite windy. This combined with highway speeds created forces that the rack design could not withstand.  The verticals were restrained by a single set screw.  Vibration could easily cause the set screw to loosen and wind forces to have their way.  This combined with bouncing on rough sections of road resulted in the verticals popping out of their mounts.

Our corrective action needed to be fashioned with items at our disposal.  But first, the stainless steel tubes needed to be bent into shape.  They had been "sprung" open.  I used a ratchet strap to bend the tube back into the desired shape.  It took several iterations of tighten to bend, release tension, test for proper fit, before we achieved an acceptable shape.

Once the verticals fit in their mounts, a drill was used to create a deep dimple in the tubing so the point of the set screw will seat in a pocket, thus creating a more secure mechanical retention.  I also used Blue Loctite on all fasteners to provide additional resistance to loosening.  In the future, I will likely create a through bolt situation, once I source the appropriate fasteners.

To further reduce the load on the system, I removed the rocket box and moved it inside the camper shell, on the back of my truck.  With those modifications, we had no further problems.  I have also increased the frequency and quality of the in-transit and post-transit inspections to see if we can catch any emerging issues before they become nasty.

I expect we will have much less drama as we locate and resolve the marginal design decisions.  I'm still happy with our choice of a Ranger Tug.  Under normal use, the issues we have encountered might never emerge.  Driving across country, boat in tow, subjects Amy Marie to forces not normally encountered.  Hopefully we can find and make adjustments in a timely manner.  In two days we will be splashing Amy Marie to start our loop trip.  She, and us, will be a stronger team when that moment arrives.