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#369508 - 08/11/06 09:03 PM
The Phoenix Rising - Disasters tend to happen in 3's
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Barry Wolk
Member
Registered: 06/17/03
Posts: 1146
Loc: Farmington Hills, MI
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DISASTERS TEND TO HAPPEN IN THREES
8-10-2006 I carelessly damaged my Mark II as I pulled it out of the garage to go to a Press Preview of the Willistead Classic. It's parked on a four post lift, in the down position during the summer as I park the Porsche on top for winter storage.
I pulled too far over and took off the Mark II emblem and left a very nasty set of gouges in the paint with the lift's support cable. I went to the Press Preview anyway.
I loaded up the Porsche and had a friend, who moves cars professionally, tie it down for me for transport. I had positioned the car so that it lent some noticeable tongue weight.
Friday 8-11-2006
My employees and I spruced up the work truck for travel. I had just had every system service and checked on the truck. I wanted an uneventful ride. I drove home and packed and loaded the truck for a fun weekend at a Concours that we helped develop.
We shortly encountered some construction that required some lane changes and the trailer handled pretty well. We made it about 30 miles when disater struck. I had been traveling in the left lane of a freeway and exited on a continuation of M-14. This is one of those left-entrance ramps and I wanted to end up in the right lane. I had a clear shot at a lange change and moved over at about 45 miles an hour. The road was crowned and slightly curved.
I felt the truck start to pull and I knew I had a problem. The trailer started to fishtail quite forcefully. I had read, and I had pacticed, using the brake hand controller in the event of a bad sway to drag the tow vehicle down in speed and straighten out the sway. I used the hand controller and it had no effect the first time. Apparently I didn't leave it on long enough as it has to build up pressure in 24 pistons. The second time I tried I got almost immediate results and the truck straightened out as I was headed for the concrete median wall.
By this time the trailer had done about 4 wags. I pulled away from the median as the 4th wag smacked the driver's side tail of the trailer against the median. That seemed to interrupt the pending catastrophy and shoot us off across the sholder and two lanes of the e-way. I was now headed for what I perceive to be a ravine. My wife remembers it as a large ditch. I was now somewhat in control. At least I was headed in the same direction as the rest of the traffic.
The ravine was fitted with a guardrail that probably saved our lives. Unfortunately, that impact tore the Porsche loose from its mountings and slammed it into the passenge side wall and rear door of the trailer.
The only thing that kept the Porsche from crashing ino the lounge was the spare tire for the trailer. It wedged the front tire of the Porsche up against the winch.
The Porsches's pretty messed up, but repairable.
The trailer suffered some structural damage, but also can be repaired. I'll have to find a donor trailer.
I believe what happen had to do with the newly installed load distributing and sway control hitch. One of the torsion bars dropped out of its socket and hit the pavement as did the chain cinch it was attached to.
One of the torsion bars, the one that hit the pavement, shows signs that it worked its way out of its socket as its wear pattern shows.
I believe what happened is that the torsion bar fell out of its socket as we crested the crown of the road. This is when there would be no tension on the bar. The hitch is fitted with a pull pin that must have worked its way out or rolled over to reveal its tapered side. The conditions must have been just right and allow the torsion bar to drop out.
The torque that the trailer went through with one of two torsion bars exerting torque on the frame was amazing. The 2" solid steel hitch insert bent to about a 20° angle. It looked like tubing that had bent. Very scary.
While this may have been an unfortunate couple of days I believe I am fortunate to be amongst the living.
BTW, I believe we have chosen the name for our trailer. It will be forever known as "The Phoenix" Appropriate on so many levels.
Edited by Peter Gariepy (12/10/07 11:30 PM)
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#369509 - 08/11/06 09:51 PM
Re: DISASTERS TEND TO HAPPEN IN THREES
[Re: Barry Wolk]
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carbdoc
Member
Registered: 06/14/06
Posts: 85
Loc: Nebo, NC
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Barry,
I grasp the magnitude of these vehicular tragedies because I understand the concepts of "one of one" and "hand-fabricated".
It would appear that you might be able to repair the Lincoln without repainting the complete car. The Porsche seems to need some fairly extensive surgerey, but I'm sure it's fixable especially if you had it insured with a reputable company.
It is The Phoenix which would seem to be of greatest concern. You just finished building it, didn't you? If it is the same trailer which I think it is, I have been following its re-birth in one of the Hemmings publications; it surely is a beautiful rig. What did the insurance adjuster make of this situation? Its "restoration" seems as if it could be the most challenging aspect of the entire situation.
Best of luck.
Jeff Dreibus
_________________________
Jeff Dreibus
The Old Carb Doctor
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#369510 - 08/11/06 10:03 PM
Re: DISASTERS TEND TO HAPPEN IN THREES
[Re: carbdoc]
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Matt Harwood
Member
Registered: 10/09/01
Posts: 1615
Loc: Cleveland, OH
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Barry, I think last week was bad for a lot of people. Between my work truck having a broken-off spark plug, to my other two cars being stranded between it and the garage forcing me to tear down my fence to get them out, to backing my car into a metal pole and smashing the bumper, I was there with you.
So I'll pass on a bit of sage wisdom that my father told me and which comforted me as I bemoaned the tragedy of my situation:
"Do you have cancer? Are you dead?"
I think maybe it helped a little. Sorry about your mishap. I definitely feel your pain. Kudos for being able to continue to the show after scratching your beautiful Lincoln--I probably would have been frantic for a week!
This, too, shall pass...
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#369511 - 08/11/06 10:15 PM
Re: DISASTERS TEND TO HAPPEN IN THREES
[Re: carbdoc]
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Barry Wolk
Member
Registered: 06/17/03
Posts: 1146
Loc: Farmington Hills, MI
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Quote:
Barry,
I grasp the magnitude of these vehicular tragedies because I understand the concepts of "one of one" and "hand-fabricated".
It would appear that you might be able to repair the Lincoln without repainting the complete car. The Porsche seems to need some fairly extensive surgerey, but I'm sure it's fixable especially if you had it insured with a reputable company.
It is The Phoenix which would seem to be of greatest concern. You just finished building it, didn't you? If it is the same trailer which I think it is, I have been following its re-birth in one of the Hemmings publications; it surely is a beautiful rig. What did the insurance adjuster make of this situation? Its "restoration" seems as if it could be the most challenging aspect of the entire situation.
Best of luck.
Jeff Dreibus
It just happened today. I'll be reporting it on Monday. I'll probably have to find a donor trailer to repair it properly.
Actually, I've been going over the repair in my mind and I think I can fix it as well as anyone.
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#369512 - 08/11/06 10:25 PM
Re: DISASTERS TEND TO HAPPEN IN THREES
[Re: Barry Wolk]
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Peter J.Heizmann
Peter J. Heizmann
Member
Registered: 10/19/01
Posts: 2310
Loc: Reading, PA
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Barry...
Looking at the photo of the trailer / torsion bar.
For the weight and size of what you are towing, it looks awfully flimsy to me.
I tow only 5200# with a Dodge Dakota. My "Reese" anti-sway & load levelling bars are "FORGED STEEL". What concerns me is the "U" Flange that is affixed to your trailer's frame. The unit I have fits entirely over the frame, and, each unit is affixed with "2 horseshoe bolts EACH" with a "steel plate on the trailer frame underside that is "pulled tight for equal torque". To boot, the sway bars fit into a heavy duty hitch, and, a receiving unit on the trailer frame.
Electronic Brake Control: Did you perform the normal adjustment after about 25 minutes after starting out on your trip? This is the "adjust the tow vehicle to the trailer adjustment so both are in "synch".
Have had my own panic situations in adverse conditions with no problems so far.
Again, based upon the photos, the trailer-to-tow vehicle anti-sway/load leveling set up looks weak considering the weight your are towing.
Glad you are OK. The car and trailer can be fixed.
Peter J...
_________________________
Peter J. Heizmann
AACA Life Member #383299
Northern Neck Region
Pottstown Region
Vintage Triumph Register
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#369514 - 08/11/06 11:12 PM
Re: DISASTERS TEND TO HAPPEN IN THREES
[Re: novaman]
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Peter J.Heizmann
Peter J. Heizmann
Member
Registered: 10/19/01
Posts: 2310
Loc: Reading, PA
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Hi, Dave...
I have no fear of the "Valley" hitch system, as I so noted. It has worked for over 12,000 miles of towing, and, as I mentioned, 5200# G.V.M. in my case.
Please elaborate about any failures you experienced, or, heard of so we can all learn for our own safety.
One thing I do know, is a safe anti-sway bar/load leveling system is a must for stability (especially for air drag left & right depending on what lane one is in when an 18-wheeler, or, bus passes you.)
I remain that Barry's trailer frame shackle-to-chain & sway bar looks flimsy "based upon the photo".
Peter J...
_________________________
Peter J. Heizmann
AACA Life Member #383299
Northern Neck Region
Pottstown Region
Vintage Triumph Register
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#369515 - 08/12/06 07:00 AM
Re: DISASTERS TEND TO HAPPEN IN THREES
[Re: Peter J.Heizmann]
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novaman
Member
Registered: 06/11/00
Posts: 2395
Loc: Mebane, NC, USA
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Peter, It isn't a case of having expericence with a failure. I've just always been lery of the idea sticking the end of the rod UP a vertical hole, therefore perfer not to use it. If the clip fails or didn't seat, the bar could walk down the hole and possible come out. The "Reese" style has the end captured in two cups.
When we were in Asheville, I'm sure while we unloaded/loaded you didn't notice what it required to unhook/hook up the bars on my truck. I can pull the bars up by grabbing the hook with my fingers and pulling. With the 3500 series truck pulling an approx. 4500lbs load, it doesn't need much load on those bars. In my case, the major thing they are doing is keeping the trailer from wanting to purpoise down the road behind me (especially on the concrete interstates).
Barrys piece on the trailer looks like mine. Remember, with the bars attached, they are trying to pull that plate down through the frame rail. The only thing I might have done differently would be to put some weld on it, just to make sure it wouldn't try walking the frame rail.
_________________________
novaman
AACA Life member
1962-1965 Chevy II Novas
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#369516 - 08/12/06 07:30 AM
Re: DISASTERS TEND TO HAPPEN IN THREES
[Re: Barry Wolk]
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MrEarl
Long Time Member
Registered: 07/14/03
Posts: 3530
Loc: NE Georgia
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Barry,
so sorry to hear of your accident(s) but also thankful you all are OK. Sounds like it could have been much worse. I'm sure you'll figure this one out too. Take care
_________________________
Lamar in Athens, Georgia
BCA- 39474, 1959 BDBCA-0021, AACA-228846  1954 BUICK "The Beautiful Buy"1954 Roadmaster 76R, 2 DR HT - DoraB, (Irene,gone down under) 1954 Roadmaster 72R 4 DR - Buttercup, Dakota, Blue Belle, Virginia, Marietta, "High Society" (thank you Paul Meyer) 1954 Century 66R 2 DR HT- "54Muscle" w/3 speed stick(thank you Jim Schilf & Norm Kortus), Mary Jane Verkauft bis ein, wer 54 Buicks in Deutschland liebt, dankt Freund 1954 Special 41D 4 DR Deluxe Sedan 3 speed- Sugar Magnolia
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#369517 - 08/12/06 10:12 AM
Re: DISASTERS TEND TO HAPPEN IN THREES
[Re: MrEarl]
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1937hd45
Long Time Member
Registered: 11/01/01
Posts: 5141
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Sorry to read about these events. Wouldn't the towed vehicle stay centered if the tie downs were crossed? Left wheel to right floor rail and vice versa?
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#369518 - 08/12/06 10:23 AM
Re: DISASTERS TEND TO HAPPEN IN THREES
[Re: 1937hd45]
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Barry Wolk
Member
Registered: 06/17/03
Posts: 1146
Loc: Farmington Hills, MI
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Quote:
Sorry to read about these events. Wouldn't the towed vehicle stay centered if the tie downs were crossed? Left wheel to right floor rail and vice versa?
Maybe. The inertial forces at work in the impact make have done structural damage to the car. Thankfully the car just seems to have superficial sheet metal damage. The trailer is going to need some serious work, but I'm up to the task.
The rub is that everything that I did held up perfectly as shown by the uneventful trip home with a standard hitch. I will rebuild.
Oh-Oh! More pictures!
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#369519 - 08/12/06 03:56 PM
Re: DISASTERS TEND TO HAPPEN IN THREES
[Re: Barry Wolk]
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carbdoc
Member
Registered: 06/14/06
Posts: 85
Loc: Nebo, NC
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Barry,
I stay permanently "behind the curve" so I didn't find your ealier thread with all of the "Phoenix" photos until just now. I, too, can now be painted green (with envy) for your skill and ability to create such a fantastic toy box. It is indeed the project I have been following in Hemmings. It must be a real "downer" to have this happen so soon after completion, but I am certain that you will rise to the task of putting wings back on the "Phoenix" and once again get her "airborne".
Jeff Dreibus
_________________________
Jeff Dreibus
The Old Carb Doctor
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#369520 - 08/12/06 05:04 PM
Re: DISASTERS TEND TO HAPPEN IN THREES
[Re: carbdoc]
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Barry Wolk
Member
Registered: 06/17/03
Posts: 1146
Loc: Farmington Hills, MI
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Thanks Jeff. Which Hemmings site has info on my trailer project?
8-12-2006
Now I'm angry. Let's see if you come to the same conclusion.
First, let me describe the way the system works. A round tube torsion bar system does work well under normal circumstances.
The 2 x 2 solid steel bar that fits into the receiver on the tow vehicle is held in place with a hardened steel shaft with a spring pin passing through a hole in the end of it, holding it in place. That shaft becomes an extension of the vehicle as it is tied directly to the vehicle frame. I believe it was bent when the trailer nearly jackknifed.
The 2 5/16" ball is mounted to the new equalizing hitch, not the hardened steel shaft, as is normal for a non-equalized hitch.
The equalizing hitch is attached to the hardened shaft through the vertical shaft drilled with additional holes for height adjustment. A proper height is selected and proper shims are installed to make the ball tip slightly toward the trailer. This angle is important because it will change slightly when the torsion bars are put in tension.
The bars are put in tension by a cam device that snugs up the chains, transferring the load equally to the trailer and the tow vehicle. You are suppose to level out the trailer and tow vehicle and then apply tension to the bars by equally counting the number of links and setting the tension devices on both sides. 8 links produced no tension. 6 links was nearly impossible for me set. 7 was just right.
Each chain tensioner is fitted with a safety device that keeps the tensioner closed. These parts did not fail. The tensioner is fitted to the frame with a set screw. They supply different length screws for various frame widths. These clamps are snugged in place, but are mainly held by the spring tension pulling them straight down on the frame.
The objective is to make the trailer and tow vehicle a unified structure so that "porpoising" is minimized. The sway control comes from the round tube connection. The torsion bar has a diameter that is smaller than the tube it fits into. It is designed to move freely when not cocked in the opening by the tension provided by the chains. The rubbing of the round bar in it's receiving tube is what gives you sway control as that resistance is what makes the tube intentionally bind when needed.
There are many times that the tension drops and the round bar is free to move in its socket. It is held in place at this time, on this model, by a tapered, spring-loaded pin that allows you to push the round bar into place without pulling back on the pin.
That pin fits into a groove in the round bar that is designed to stay engaged with the groove, keeping it from falling out of the socket.
After a sleepless night I went back to the shop and made a closer inspection of the mechanism.
My first observation was that the pins were nowhere near as long as they could have been, based on the depth of the groove. Even so, they should have stayed in.
I then observed that the beveled face of the pin didn't line up with the locating grooves that are supposed to firmly position the pin.
If the beveled pin were allowed to rotate 180° the round bar would never stay in as it would simply push the pin back by sliding down its ramp. These pins didn't rotate 180°, they only rotated about 20-25°, enough for the pin to work its way out and disengage the safety device.
To check my hyphypothesis I used two metal plates with straight edges inserted all the way into the locating grooves. You can clearly see that they are not within any tolerances that I (or anyone else) would find acceptable.
This manufacturing flaw wasn't the total cause of the failure though. The springs installed to keep the pins in place are made of either very cheap or very thin spring steel. They offer little resistance to the pin being pushed out of place.
This is the last link in the failure. The top round bar is the one that fell out. The one that stayed in has a nice crisp edge while the one that fell out has a ramp-like edge that would definitely shorten the effective length of the pin.
In my opinion it was the cumulative manufacturing flaws that led to the torsion bar dropping out of its socket.
When the passenger side torsion was lost the torque of the remaining torsion bar put the trailer into a severe pull to the side that remained. It's indescribable how I felt at that moment as I've never encountered that effect before. Instead of diminishing sway the remaining bar was inducing it. Had I not applied the trailer brakes the trailer would have continued on its circular path clearly leading to a flip of either or both of the vehicles.
Does this qualify as negligence on the part of the manufacturer? I'm sure my insurance company will go after them to recover their costs. Is a retailer responsible for a product they sell? Keep in mind that this product is marketed and sold as a safety device. Is this an issue for NHSTA? Is that who would regulate this product or would this be a Product Safety issue?
I've heard from four people that they have observed round bar hitch failures, too.
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#369522 - 08/12/06 06:33 PM
Re: DISASTERS TEND TO HAPPEN IN THREES
[Re: R W Burgess]
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Barry Wolk
Member
Registered: 06/17/03
Posts: 1146
Loc: Farmington Hills, MI
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The tow vehicle was an F-450. It towed the trailer just fine. A heavier truck would have made little difference. I take that back. Maybe a semi would have withstood the torque. Maybe.
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