Frame Work

Work on the frame to: repair a cross brace with broken welds, add base plates for leveling jacks, add a 2" receiver tube (adding a new channel cross-brace to replace the existing angle), and add an angle to mount a below trailer spare tire winch. I opted to mount the leveling lacks parallel to the frame, rather than perpendicular which seems to be the norm. I can always rotate them with an adapter plate. (I also opted against contemplating an aluminum frame for a number of reasons...)

The before picture.

Cleaned up the stressed weld to re-weld it.

Cleaned up the broken weld to re-weld it.

Clamping the joint prior to weld.

Welding the joint (most generous friend helping with Arc welding). For those interested, used 6010 rod. 3/16" for the finer bits, and 1/4" rod (I believe) for areas needing some more oomph. I think we were running the 3/16" at about 70 amps.

Frame in front of the house, using a grinder with a wire wheel to take off loose paint and rust. I'm going to use the POR-15 paint system. Degreasing and metal prep is next.

Showing the frame after wire wheel, degreasing, and the metal prep. The metal prep is a phosphoric acid I believe that etches a bit.

Frame in garage, being rinsed from the degreaser or the metal prep... can't remember.

Now, adding the bumper. 3"x1.5"x1/8" steel tube.

Awesome friend Arc welding.

Adding the receiver tube. I had a few bracing pieces waterjet cut to add further structure. I don't ever expect to tow with the trailer, but just in case... I included hitch chain holes. They're angled back to hide them a bit.

Adding 3/16" thickness steel plate for leveling jack mount plates. I mounted them to have the leveling jacks parallel to the frame. I think this 'might' not be the best for side to side wobble? But, they're really for leveling adjustment. The placement of the rear jacks would allow for adding the available cross-brace. The parallel mount means they're tucked nicely under the Casita at all times.

Tack weld for the end caps on the bumper. We came back and welded them fully.

Grinding down all of the finished welds... and taking off any weld splatter.

Final smooth result around the bumper.

I re-degreased and metal prepped where I sanded. Washing it off.

Painting with tongue jack still on to be able to get under. I then took it off to be able to paint under its attachment plate, and to get in under the receiver to paint.

Half painted with POR-15. Beautiful finish next to the prepared old finish. (Note the welded on axle... that's a future project to replace)

I decided to add neoprene tape to the top of the frame componentes that will be in contact with the Casita bottom. It will give a bit of cushion/friction.

Completely painted now... Almost ready to have the load of a Casita again. (I still have to bolt on the spare tire winch under the back... and other things I've forgotten probably.