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03.03.2021, admin
Here are 2 tips to make your trailer frame stronger. There are many suspension options available, yet leaf springs are still the most common, and arguably least expensive. They are the workhorse of trailer suspension, but they are often hung wrong. But, if they work, how is it wrong? First some background. If the stress is below the material limits, the beams hold just fine. If the stress becomes greater than the material limits, then the beam will bend or break.
Failures breaks or bends usually start at stress concentration points � where stress becomes high in a small location. Figure 2 shows an axle mounted under a main frame beam. Wheels, tires and crossmembers are removed for clarity.
Dark blue is low stress, and red is high stress. Red does not mean instant failure, rather it shows where stress is much higher. In Figure 2 , you can see some stress concentrations that appear as smallish red areas. Other stresses around them indicated by greens and blues are not as high, but because of the construction, there is concentration of stress in areas adjacent to the spring mounts.
The back mount shows more because of the angle of the pivoting spring shackle. Side note: Figure 2 is a static, vertical load analysis. Dynamics like bumps or braking add stress, and change the look some. This stress distribution is typical of leaf type trailer axle springs. Values change and beam sizes change, yet distribution is pretty similar. Notice how stress in the main beam is higher on the top and bottom of the beam as Aluminum Boat Trailer Hanger Database compared to the center side areas. Combine these ideas of stress distribution with the Aluminum Boat Trailer Spring Hanger Kit fact that welding weakens the areas immediately around the weld.
If we weld in areas of high stress, we effectively decrease strength of the beam. OK then, how do you weld on the spring mounts? One way is to weld the brackets on both sides � only. For a lot more detail on this topic, we have an article which discusses the Engineering involved. Another key to strengthening a trailer frame is reducing or eliminating the stress concentrations. Failures almost always start in areas of stress concentration, so if we get rid of them or minimize them , the frame is stronger.
The Trailer Plans from and Mechanical Elements have always had a buffer piece between the main frame member and the spring mounts. Customers ask about it, so here is a graphical engineering analysis showing why. Start by looking back at Figure 2. Note the points of red on the main beam. You can ignore points of red on the spring mount brackets because they are typically higher strength steel. The same stress means less to them. Just that one strip placed between the brackets and the frame changes the stress.
Note there are no red areas on the main beam, and only small amounts on the inserted buffer piece. This trick can be done with a strip of steel like in this example, or with one leg of angle iron or with something more substantial. The point is stress in the main beam spreads. We depend on the main beam to support loads on the trailer, so if we can reduce the highest stress on that main beam, then we have strengthened the whole trailer.
Make the buffer piece at least as thick as the spring mount bracket material. Extend the buffer beyond the spring mount � more the better � but there is a diminishing return. We find 5 or 6 inches out both sides from the bracket works wonders. Finally, weld the buffer piece to the main frame beams in stitches only along the sides � not on the ends. Short, spaced welds stitches are great.
Two other ways to spread the stress include your choice of trailer main beam material , and the length of the springs. The buffering trick above to spread stress of the trailer axle springs does more than just disperse stress concentrations near the brackets. These 2 images below show how it spreads stress all around the beam.
If you weld and weaken one side, it weakens the full beam. Cut one side, and the others have to make up for it. Also, if you strengthen one side, it adds strength to the whole beam. Now you know 2 great tips for making a better mount for trailer axle springs. For a third tip, use longer leaf springs.
Plans Info , Solutions! Sometimes looking for the right plans for the trailer you need is a needle in a haystack. Every site has something, but not exact. If you ever doubt the sanity of safety chains, then see this example of where a single trailer chain literally saved lives. The story is amazing from all angles �.
Mechanics Tips. The Best Reason to replace old or worn trailer tires is personal sanity, because who wants to deal with it on the side of the road? Thanks for this great article on trailers! Really makes sence on what axels you choose. Was going to use tork but now spring makes more sence , Thanks JimR.
Jack August 7, PM. Gus October 3, PM. Thanks for the great info ME. Mounting springs on angle also allows adjustment of final axle position later in the build. Also, any advice on avoiding rust between these flat surfaces of steel? Thanks, Gus. The Mechanic October 7, PM. Stitch welding is a great solution anytime the weld joint is long but not under a lot of load � like springs on angle.
Gus May 2, AM. Should I really go with 10mm thickness angle to match the spring hanger thickness? Really appreciate the advice.
Mechanic May 2, PM. I know a lot of people do just what you say � and it works mostly. I saw one the other day that I pointed out to my wife as we drove by. Bring some focus to Figure 4. Does it have to be 10mm? Anything helps. Same thickness is a good rule of thumb. Good luck with your project. Nabil May 9, PM. But the spring hardware is all steel. Would it work to do a dual stack of plates? One steel for the spring hangers to weld to.
Then a second of aluminum welded to my main beam for spreading stress as well as tapping threads into to bolt Aluminum Boat Trailer Hanger Quality the steel plate to?
Mechanic May 11, AM. A stack is fine. The top and bottom of the beam are the highest stress, so bolt through the sides. Finally, make sure there is a barrier between the aluminum and steel � paint, plastic, something to avoid galvanic corrosion between the dissimilar metals. Ivan Vuja May 13, PM. Thanks so much for this useful article! However, I do have a question about welding on the hangers. So should you also tack weld, or would that be the same as welding across and should be avoided?
Mechanic May 14, AM. Maybe I need to write a little more to clarify that. Figure 2 shows the hangers directly on the main beam. Figure 4 shows the hangers with a buffer piece between them and the main beam. You can weld all around the hangers onto the buffer piece, then weld the buffer piece to the main beams only on the sides.
The recommendation is to avoid welding on the top and bottom surfaces of the main beam, not the other surrounding members.
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