Roller bunk project:

[Pale Rider]

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-Roller-Shaft-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...

[Pale Rider]

a few more:
any thoughts?

[Insanediego Joe]

This is exactly what hydrotoys and I have been talking about doing. Press on andy gpr lead the way! Ill be copying what you do here.

[Pale Rider]

This is exactly what hydrotoys and I have been talking about doing. Press on andy gpr lead the way! Ill be copying what you do here.

couldn`t have done it without talking with you guys and your input/help!, thanks joe and mark!

I just ordered the "pal nuts", 40 of them , the press on caps...

I think the very most front roller might not come in contact bc of the upward curve, but we`ll see... lots of labor and waiting on some stuff...

(my rear crossbar is rug covered to protect the keel/bow. it has always been like that on every ski trailer...)

[XLT Chad]

Atta Fella!!! Blazing a trail again. Keep up the good work Andy!

[Pale Rider]

Atta Fella!!! Blazing a trail again. Keep up the good work Andy!

haha, it keeps me busy!, can`t keep a good skilled union man down ya know

[smokeysevin]

I like it, where did you get them from?

Sean

[Pale Rider]

I like it, where did you get them from?

Sean

Hey Sean, here ya go:

http://www.easternmarine.com/5ft-Poly-Roller-Bunk-Assembly-1-pair-86145/

[Pale Rider]

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 Pal 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.*

Crazy stuff huh?

[Hydrotoys]

So,
the more I think about this, the more I think You should consider a mixture of bunk rollers. Without looking I think you can have 2-3 wide up front, where the chines seperate. It's in back, where only a single roll will fit, and causes the issues.

Consider running the singles in the rear, and size your front area for 2 or 3. This will add some stability up front, where you "bang" the hull up on the trailer after a long day of riding. The rears will self-align, and will find their groove pretty easy.

[Pale Rider]

So,
the more I think about this, the more I think You should consider a mixture of bunk rollers. Without looking I think you can have 2-3 wide up front, where the chines seperate. It's in back, where only a single roll will fit, and causes the issues.

Consider running the singles in the rear, and size your front area for 2 or 3. This will add some stability up front, where you "bang" the hull up on the trailer after a long day of riding. The rears will self-align, and will find their groove pretty easy.

before I started I did a mock test, the rear set (3 wide) would still touch the chines/flat area leaving the center rollers in limbo. a front single roller would fit up inside between the chines leaving the remaining center roller useless... Think about it this way: any 3 wide set up will be resting on the chines, essentially raising the ski above the center rollers anywhere on the hull. I`m positive the single center row of rollers will act just like any 2x4 bunk on edge placed between the chines...
I could always add/subract if necc after the trial fitting and assy is complete. The only real area of concern would be the very front where the chines are at their narrowest, but after the whole ski is resting on the rollers the front few won`t even be touching the hull bc of the upsweep in the hull...


this morning:
Cut and dressed the roller axles/shafts. waiting on Pal nuts for assy...

[Hydrotoys]

How did you get the Pal nuts off the shaft. You had mentioned it was pretty tough.

[Pale Rider]

How did you get the Pal nuts off the shaft. You had mentioned it was pretty tough.

refer to post 9 and the first pic...

the first one I removed, I cut and X into the end without killing the shaft with the 4" cut off wheel, and then peeled it off with a sharp small chisel until I said to self, that was to dam hard and time consuming and saw that I could easily bend down the edges of the pal nut and release the tangs to the point where I could place a small sharp screw driver into the groove/slot/above the tang and use the roller/wheel as a fulcrum point to pry up the pal nut... this method went very fast...

[Pale Rider]

roller bunk project 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...

[Pale Rider]

and the last few: