Boat loader for the Disco

**awabbit6** · 1st October 2009, 07:44 PM

Well after much deliberation and a poll to decide how to transport our tinny as well as the camper trailer. I decided to modify my existing roof rack to take a bolt on boat loader. I had two weeks holidays - should knock it over in no time ...

... so I thought ...

The design is based on the Custom Boat Loader, Rhino boat loader and Tinnie Tosser designs. I think I have taken the best of each and put them into mine.

So here it is so far.

I started by machining some threaded inserts to weld into the existing rack to bolt the loader to.

Then lay out a basic frame.

A bit of a mock-up to sort out roller positions

The motor and gearbox assembly I ordered arrived but instead of having the 120W motor I wanted, I was given a free upgrade to a 500W motor. It was huge and required nearly 60A to run it. Too big for what I needed so I sent it back ...

After a couple of days of machining delrin bushes and cutting end plates for all three rollers, the front roller was fitted.

Then the rear roller ...

And now the new 250W motor (still bigger than I requested but I can cope with 30A) is fitted up.

Next job is to fabricated the carrier for the bushes on the motor end of the main roller (I've already machined up the drives with internal key way) and then fit the outer carriers.

While I'm doing that, I'm also sorting the wiring and switching out. I've purchased a remote control unit from China that arrived yesterday I've worked out how to drive the relays that will switch the motor.

So it's all coming together. Still a lot to do before it's ready to be tested. I hope to spend at least one more day on it before I have to go back to work on Monday. I'll add photos as it gets closer.

**LandyAndy** · 3rd October 2009, 02:43 PM

Great work!!!!!!
Nice little Hot Rod you have there.
By the way,that shed is WAY TOO TIDY

Looking forward to seeing pics of the boat loader in action

Andrew

**awabbit6** · 4th October 2009, 10:34 PM

Originally Posted by LandyAndy

Great work!!!!!!

Thanks Andrew. It'll be great if it works!

Originally Posted by LandyAndy

Nice little Hot Rod you have there.

Unfortunately it spends too much time parked right there! Hopefully next year I'll dig it out more frequently and do a bit of club competition.

Originally Posted by LandyAndy

By the way,that shed is WAY TOO TIDY

... tidy shed = tidy job ... well at least that's my experience anyway. I never do a good job when I'm working in a mess.

Originally Posted by LandyAndy

Looking forward to seeing pics of the boat loader in action

Me too!!!

**awabbit6** · 4th October 2009, 10:49 PM

The bulk of the fabrication is complete now.

Saturday's effort saw the completion of the main roller carriers at the drive end.

The aim for today was to complete the outer carriers and fit the main drive rollers ... It was a big day, but I got there.

Back to work tomorrow, so the remaining jobs will have to wait. Still to do:

Wiring
Roll pins to lock the main rollers to the drive
Rope guides for the main roller
Fit attachment points to the boat
Fit the rack to the car and set up the ropes

It doesn't need to be finished until the second week of December, but I'd like to have it well and truly finished and thoroughly tested by then.

**dullbird** · 5th October 2009, 10:25 AM

That looks like some really nice workmanship right there!

**awabbit6** · 23rd November 2009, 04:57 PM

Well it's been a long time since I posted the pictures of my boat loader fabrication, and it still isn't finished! ... getting close though.

I've finished the rack and got all the ropes made. I put the rack back on the Disco on the weekend.

Just have about a day's work to make a fulcrum plate to fit in the tow-bar receiver which will double as an outboard mount on the spare wheel.

Getting there ...

**awabbit6** · 6th December 2009, 09:04 PM

I've finally done the first test of my boat loader .... And it works!

I expected to have to make some minor adjustments but none were necessary. The only minor problem is that the rings at the top of the rear ropes that run along the main ropes are a little big and clip into the front hooks when they shouldn't. I'll just change the front hooks for different ones and it should be fine.

I went for a run up the road and once in the car, I didn't even notice the boat on the roof. Can't see it from inside and it doesn't even feel heavy around corners.

I'm just uploading a video to Youtube and will post a link once it is done.

Final job is the outboard mount on the spare wheel. Should be done tomorrow.

**awabbit6** · 6th December 2009, 09:15 PM

Here's the first video ...

[ame="http://www.youtube.com/watch?v=OCcLJzZocdI"]YouTube- Boat Loader First Test[/ame]

**weeds** · 6th December 2009, 09:25 PM

nice work paul

**awabbit6** · 6th December 2009, 10:39 PM

[ame="http://www.youtube.com/watch?v=9uduY1gVzTU"]YouTube- Boat Loader First Test Removal[/ame]

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