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Old 05-14-2011, 10:50 AM
Pale Rider's Avatar
Pale Rider Pale Rider is offline
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Default Roller bunk project:

ok, picked up a set of these non marking roller bunks, and I`m going to try something a bit different.
After removing one of those pressed on end caps off the roller axle/shaft I was able to fool around with the set up.. The Blue plastic piece is a gauge the width of the roller and the height of how much the roller sticks up from the C channel so I could gauge how close the metal C channel sides would be to the chines.
The other reference pics are different placements of the roller back > front...
There is a good 4ft of flat area from the rear towards the front, after that the hull starts to sweep upwards and the front sets of rollers may not even touch at that point.
Then I proceeded with a simple mock up to see exactly how the mounting brackets and holes in the C channels line up..
The placement of the roller assy is more towards the rear of the ski/trailer and that means that there will be on roller beyond the contact point of the hull. This is to help prevent the Bow/hull from hitting the rear crossmember...
I don`t think there will be an issue with that bc the rear of the trailer is always under water and I generally float the ski on...

hopefully this is a decent way to support the hull and not kill the bottom any more than it is...

I now need to see what hardware is avail for reassembly.

the roller axles/shafts are 5/8. they are 6 5/8 long. As shown in the pic the center line and roller in place. If these are cut exactly in half I believe I can install new pressed on end caps to give it that finished look or another suitable way...

http://www.easternmarine.com/5-8-rol...pal-nut-10801c


The plan is to omit the inner and outer rows, use the rollers to add more to the center, creating a single roller center bunk set up...
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Last edited by hydrotoys : 05-17-2012 at 10:07 PM.
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Old 05-14-2011, 10:52 AM
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a few more...

any thoughts?

I`ll tell you, that is a lot of work to remove those pressed on end caps without touching or putting any pressure on the rollers.
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Old 05-15-2011, 02:22 PM
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did a little more today:
Found an easy way to remove those "pal nuts". Collapse the pal nut right where the tang bites into the shaft by bending the edge down with a small punch, then take a small screw driver and stick it into the slot and work the pal nut up and off the shaft...
Measured and layed out all the holes to be drilled. Made up a template to simplify things followed by checking the dimensions. Cleaned all the burrs off. Test fit each hole.
Measured all the shafts and made a "cut line", again with a simple template, followed by measuring/checking. Will cut these another time... Measured and drilled the mounting bracket angle. done for today...

shown is a little cardboard mock up to show the distance of the sides and pla nuts in relation to the hull chines...

Note* these will not be made to swivel. These will be hard bolted just like a set of carpeted bunks.*
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Old 05-16-2011, 08:50 AM
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this morning cut and dressed the roller shafts/axles...
waiting on Pal nuts for assy...
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Old 05-17-2011, 06:24 PM
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Default roller bunk conclusion:

The Pal nuts came in a little earlier than expected, so off to the garage for some work:
I used some cold galvanizing spray to shoot the exposed edges of the recent holes drilled, and started assy of the roller bunks. Installing the new Pal nuts was a breeze. Take a large enough C clamps, hold everything in place, and tighten the clamp, done!

I had left the vertical carpeted bunks in place while I set up the new rollers. Also loosened the U bolts holding the vertical bunks and used a floor jack to raise the bunks/ski and retightened the U bolts to give myself plenty of working space...

After measuring/centering/pivoting and going over it again and again, one more final inspection and checking roller operation, I tightened everything down for the final time... pushed the ski back a few times and winched it back onto the trailer to check alignment.
so far so good, here`s a few pics...
Well this concludes this project... whats next!!!???
clearance looks good all around...
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Old 05-17-2011, 06:25 PM
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and the last few:
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  #7  
Old 05-25-2011, 08:32 PM
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These rollers work like "Butta"!!!

even tho the ramp is a very low incline, the ski still wanted to roll off as soon as I released the winch, Whoa!
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Old 05-07-2012, 04:44 PM
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Thanks again Andy for all the pics and instructions. I'm going to eventually upgrade mine to this as well.
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Old 05-07-2012, 04:57 PM
Robsauto2 Robsauto2 is offline
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Hello, I have a purty little boat!
 
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I bought the same roller bunks, don't like the way they ride on my GPR hull chines, may do the same thing as Pale. Great job Pale!
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  #10  
Old 05-07-2012, 05:44 PM
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no problem fella`s!
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