The technical project for the week has been to replace the roller spring in our rear slide topper/window awning. A week ago while camped at Stony Fork the awning roller spring broke, during the middle of the night without apparent provocation. Consequently, the awning unfurled and no amount of rude language would convince the fabric to return to its coiled state in the housing. I couldn't drive the coach with the awning in this manner, so Terry and I removed the whole awning assembly from the slide. I called Carefree of Colorado, the manufacturer of the awning, and described the problem. Carefree would not agree to repair the awning under warranty. First, the 4-year warranty ended 5 months ago; second, I am not the original owner of the unit. Dang. They did
provide me with a part number and a list of Carefree dealers in the area. The first dealer I called said he had the part on his truck, but he was a mobile service guy and would charge $60 to bring me the part (his usually house call fee) plus labor to install, plus the cost of the part, plus the shipping charge to replace the part he already had in-hand. Thanks, but no thanks. The second guy I called said he had a complete assortment of Carefree awning springs, but when I described the specific application, he said he didn't have it: "Those springs never break". That's encouraging. Finally I called Buddy Gregg Motor Homes, a Country Coach dealer west of Knoxville. They had three in stock. Furthermore, they had a demo coach coming to our rally in Sevierville and could put the part in the storage bay. Sweet! It turns out that the demo coach had the campsite next to ours reserved for the rally. Free delivery to our back door. Extra sweet!At this point it gets ugly. The spring must be installed in an aluminum tube, tensioned to a certain specification and then all the parts
re-installed on the coach slide. Easier said than done. I had instructions telling how to install the awning parts to the coach, but the roller assembly, as originally supplied from the manufacturer, has the spring already installed and is pre-tensioned. I had no instructions describing how to install and tension the spring in the roller tube. Ok, I used to be an engineer, and there were 25 other Country Coach owners parked within 100' of our coach, all offering advice. This is doable. OK, the last part about the other owners probably wasn't a good thing. But I took it apart, I should be able to put it back together. That's when one of the other owners observed that my old spring was coiled in one direction, but the new spring was coiled in the opposite direction. Only one broken spring came out of the roller and it was tensioned on the left side; the Carefree guy only gave a single part number and said it was a left-hand spring. The label on the new spring had the correct part number and indicated "left". But there was no way I could correctly tension the spring if I installed it on the left side. The only thing I could figure was that a mirror-image, right-hand spring, had been mis-labeled at the factory. Either that or an assembly line guy or a parts guy likes playing cruel jokes on motor coach owners. It was now Saturday afternoon and there was no way to get a replacement part before Monday, short of calling the mobile service guy. I wasn't that desperate. Not yet, anyway. After a great deal of pondering, it became apparent that I could install the spring on the opposite side, the right side and tension it in the opposite direction than the original spring. I went through all the mental gymnastics of determining how to install the spring, which direction to tension it, which direction to roll the fabric and the straps, how to hold it in tension while I reinstalled it to the slide, etc. Thankfully, all the other CC owners had left the park to go to dinner, and I could talk to myself and draw pictures with my fingers in the air without anyone I knew thinking I was insane or talking to me or distracting me. Finally, after I thought I had it all figured out, I called Dorcas out to go over my thinking, and so she could be a scapegoat, if things went all wrong. The final assembly was actually fairly anticlimactic. I worked from the ground on the ladder, and Dorcas was on her belly leaning out over the edge of the coach. We had it all back together and installed on the coach before everyone returned from dinner. It now works much better than it did before; much better, in fact, than the corresponding front slide topper awning. When I get home, I think I will try re-tensioning and lubricating the forward awning. If it breaks while tensioning, I can repair it in the sanctity of my own driveway, with all my own tools. I would rather have it break there, while I have time to get the part and don't have to get anywhere, than I would repairing it on the road .... again.
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