Broke My RV Ladder - Check Out The Monster Repair

[Wiredawg]

Friends,
Bought and installed a permanent satellite dish on my DRV yesterday and while on my way down, it cracked and bent in. The ladder is rated at 300lbs and I'm 242, but I have to say with all the projects I've done on the RV: installing 3rd A/C unit, installing 4 slide out covers, cleaning/treating the roof each year, and repairing the roof from a renegade tree. I don't blame the ladder quality.

I got down safely and spent some time looking for a replacement, but, whilst looking, I reasoned the replacement wouldn't be any stronger. So, I decided to repair it. I needed a 7/8" OD pipe; ID of ladder pipe is 15/16". Went to HD and no luck in electrical as 1/2" conduit was too small and 3/4" ID conduit was to large OD. So I went to plumbing and found some heavy 1/2" ID which had OD I was looking for.

I removed the ladder and completely disassembled it. I clean cut the two breaks on the ladder where I would measure, cut, and insert the heavier pipe inside of the ladder pipe. It was a perfect fit. It weighs a few pounds more... this baby won't break again.

I wished I thought to take pics of the damage, but I did take pics of repairing it.
The area broken.
The ladder on its side drilling holes for steps

This is where it failed, the third step down

The whole ladder

The original sized ladder piping

Here's the beef,

Tomorrow, I finish drilling the sides of the steps...that thickness takes a while to drill.

Watch those ladders...its a loooong way down.

Cheers, Ron

 

[HPSimpson]

How about getting chrome molly tubing comes in many thickness. Looks like broke at mounting area for step looks pretty thin there Ron.

 

[TFucili]

Dang, that could have been ugly. Glad it looks like an fairly easy fix.

 

[Wiredawg]

Dang, that could have been ugly. Glad it looks like an fairly easy fix.

Tom,
Yep, it was pretty unnerving when it happened and it would have been a long way down. I have high confidence in the repair and it only cost $16 for the pipe.

How about getting chrome molly tubing comes in many thickness. Looks like broke at mounting area for step looks pretty thin there Ron.

Homer,
I guess they keep these things light using the thin wall stuff. The pipe I found is actually the perfect size. I need to get a couple more bits... this bigger pipe is a bear to drill.

Cheers, Ron

 

[HPSimpson]

Ron, You know best in selecting the repair material you are the boss on this project. I really glad you did not fall and have another injury thanks for that, oh have you though anymore about fixing some kind of lifting device before you ding yourself up.
I kind of figure with all the tools you would have a drill press.

 

[Wiredawg]

Ron, You know best in selecting the repair material you are the boss on this project. I really glad you did not fall and have another injury thanks for that, oh have you though anymore about fixing some kind of lifting device before you ding yourself up.
I kind of figure with all the tools you would have a drill press.

Always appreciate suggestions... I do have a floor drill press, it's just hard to hold this bulky thing on it, I might've whined a little about drilling it... and the mancave is in a no whining zone. Busted!

Cheers, Ron

 

[Cummins12V98]

Dang I have the exact same ladder. DRV replaced mine at the factory. I am very methodical going up and down it.

thanks for the post!

 

[Wiredawg]

Dang I have the exact same ladder. DRV replaced mine at the factory. I am very methodical going up and down it.

thanks for the post!

Ron,
Are you a pretty good sized boy too? Nothing like breaking the ladder to break your methodology. Long ago I was a telephone installer in the AF, so climbing poles with gaffs and using ladders was/is second nature. Why did your ladder get replaced?

Cheers, Ron

 

[Wiredawg]

Friends,
I believe I've figured out the major contributing factor for the RV ladder failure: The breaks occurred on the rung I hang my folding ladder from. Although the folding ladder is securely attached to the RV ladder, I believe the bouncing and movement of the rear of the RV applied ongoing forces to the failed area, stressing it.

Anyhoo, that's my theory that I believe explains a lot. Better for me to figure this out at home than lose the ladders in traffic and cause injury or death.

Cheers, Ron

 

[GCroyle]

Ron,

Really glad you didn't experience gravity and test that ankle repair.

And what's the white electrical boxes on the shop wall?

Gary

 

[Wiredawg]

Ron,

Really glad you didn't experience gravity and test that ankle repair.

And what's the white electrical boxes on the shop wall?

Gary

Thanks Gary, me too. Those are inverters/ controllers for my solar electric system... 51 panels mounted on the roof of my shop.

Gonna finish the ladder, remount it to the RV, and get my tools and materials off the roof from the satellite dish installation. Nothing like side projects to keep life interesting.

Cheers, Ron

Cheers.

 

[GCroyle]

Ron,

Due to situation I also went in search of "side projects" and pulled out my collection of Dexter disc brake spare parts. These all came off of removed axles and I was able to get the brake hardware.

If you had Dexter axles roughly 4-7K lbs No. 11 axle with Nev-R-Lube bearings you're looking at the brake parts to convert electric drum to disc minus the lines, hoses and actuator. I've popped all the pistons and cleaned them up. The hubs yes, two sets long story on that. Those are cartridge Timkens. The last pic is a, electric brake equipped axle getting new brakes and I test fitted the hard parts just to show what can be done. Those Dexter 4 piston brakes are pretty massive brakes. You can see the electric wire coming down the swing arm.

Bench time, cleaning parts putting them in good for storage condition. These calipers are pretty easy to work with once you learn the secret handshakes.

Gary

 

[DavidC]

Ron, is the Satellite pre-wired ?. I agree with the ladder theory on the RV ladder. I had a bicycle carrier on mine and it broke two of the stands.

 

[Wiredawg]

Ron, is the Satellite pre-wired ?. I agree with the ladder theory on the RV ladder. I had a bicycle carrier on mine and it broke two of the stands.

Dave,

Yes sir, its pre-wired on the roof. Yep, I think some of the ladders aren't as resilient for carrying items.

Cheers, Ron

Yes sir, its pre'wired... pretty easy installation... only a couple hours,

 

[Cummins12V98]

Ron,
Are you a pretty good sized boy too? Nothing like breaking the ladder to break your methodology. Long ago I was a telephone installer in the AF, so climbing poles with gaffs and using ladders was/is second nature. Why did your ladder get replaced?

Cheers, Ron

I'm just under two Franklins. I honestly don't remember what the issue was, seems like it came bent from the factory.

I have never hung anything off mine.

I can see how it would break at that location with two screws placed like there are.

 

[Wiredawg]

Friends,

Just thought I would throw another thought out there... While reattaching my RV ladder to my RV, I was thinking about the 300LB load rating and what's missing. First, I think the load rating is for brief application and no permanent load carrying. Second, nothing I've read talks about dynamic loading, when my 60Lb aluminum trifold ladder, fastened securely to the TV ladder, has a jackhammer affect vertically and horizontally as the RV hits bumps and sways during turns etc...

Just a few things to ponder as we mount bikes, ladders, Flag Poles etc to our RV ladder racks. If you are using your's to carry stuff, might want to inspect it periodically for fatigue, slight deforming, loose or damaged attaching hardware.

I guess I've whooped this hoss enough.

Cheers, Ron

 

[Cummins12V98]

Ron, are you trying to convince your self "YOU" had nothing to do with the failure???

 

[Wiredawg]

I'm a dainty 240lbs,

But joking aside, I do think I likely contributed to the failure through high use. From a configuration perspective, the failure point on mine is step just above the halfway point, and tubing failed exactly where the screws holes attach the step to the ladder. Max stressing applied when you come off the roof and are getting vertical on the ladder, so your body is further out, applying more horizontal stress to the tubing.

Just climbed it and no more movement when stepping, off, and stepping. One more thing improved on my RV.

Anhoo, both on the joking side and serious side, yes.

Cheers, Ron

 

[TFucili]

Plus, you took .0001 lbs off your pin weight

 

[Wiredawg]

Plus, you took .0001 lbs off your pin weight

Funny you should mention that, I was gonna ask if adding extra weight this far back would cause handling problems. Twisted minds think alike