After many phone calls and going to caravan dealers looking for a bike rack to suit our expanda, I decided to have ago and make our own bike rack because there was not one avalible for purchase from Jayco or any caravan after market dealers.
This bike rack was many hours in the making and a few beers have been spent here with my mates, but now its all paid off after about 1 year of trial and error.
Before anybody attempts to copy this bike rack make sure you stregthen up the rear bumper mounts on the chasis, don't rely just on the factory mounts. I still have the factory mounts for the bumper bar there but I have added 4mm square tubing, 50mm inside by 350mm long, welded to the standard bumper bar mount and the chassis of the expanda for extra support. Take note though some of this extra extention has to been grinded off so it matches up with the factory mount and then welded to the chassis.
The mounting that I have used is the same thickness as your rear tow bar that you would have on any 4x4 or Reece Hitch, so therefore is like having two tow bars welded to the chasis to hold the bike rack on the rear of the caravan. These mounts are more than strong enough to hold more that the weight of bike racks thats for sure.
For any one thats thinking of modify their van to match mine, just remember that it will need an engineering certificate to get insurance. :mod:
If you choose to attempt to make a bike rack make sure you first purchase a weight distrubition hitch, this will remove the weight of the bike rack at the rear and evenly distribute the weight throughout the length of the van. This is a must otherwise the van will sway all over the road. Trust me I found the out the hard way at first.
But since the weight distrubition hitch was put on the A frame of the van its all been smooth towing and you would not even know that the van is on the back of the 4x4.
I have the ezylift weight distrubition hitch system, for the simple fact that it is its cheaper price, better quality made, better that the Old Ausie Reece hitch which is now made in China and the quality is just not there anymore compared to the Eazylift.
I bought the main frame of the bike rack from Anaconda. I also bought an extra base, one for the back of the 4x4 and one I had to modify to suit the bike rack on the caravan.
Also with the bike rack being removable it also helps when storing because of a length issue were my van is stored.
The hinge is the final design after 3 that failed. This one opens a full 180'degrees and has not bent yet. I found that when the bike rack is open with the weight of bikes and the kids hanging and bouncing on the bike rack arm, the hinges were failing. Hense the reason I have used 10mm plate and also a jocky wheel to support any unwanted bouncing from the kids.
Also the hinge is offset when pivoting to alow maximum strength and opening further than 180'degrees.
For more detailed pictures see link below.
http://www.expandasdownunder.com/album.php?albumid=12
Since these photos I have added some Led lights and have moved the number plate which I will post at a later date. So far I have done about 3000Km's and it all appears safe and correct at this stage.
If you need any info though let me know and I will try and guide you the best way that I can!
I take no responsability for any advise that I have given and if you chose to undertake any modifictions you do so at your own risk.
Tow Safe!
Skip
WA
