Dart 15 Forums

Charles Watson wrote:

I've just taken my trolley to bits, as the hull supports were working loose from the connecting tubes. They have obviously been mended before (I don't think the iron bolts are orderable part numbers!!).

As the holes in the glass fibre of the hull supports are enlarging I think I'll need to strengthen them. Is the best way to just put glass matting over the holes & re-drill, or try filling the whole area with epoxy, to give more strength, or some other cunning ploy ?

George Stephen replied:

Hi Charles,

Originally, trolley hull supports were joined up with the alloy tube by 2 long rivets. These go through a relatively thin amount of glass fibre, and the strain can prove too much - on mine both rivets on one side pulled through the glass fibre, removing quite a large area of glass fibre around one rivet, a smaller amount around the other.

Having first noted where the tube had originally fitted in the support, I used a lot of glass fibre matting and resin to repair mine, taping up the tube side to keep a tight fit on the tube, and spreading fibre and resin thickly over the holes and around the whole of the curve on the other side - right into the narrow ends. After all was set I then clamped the tube in its original position (not easy!) and drilled through the newly repaired patches. I sanded the top side to some resemblance of flatness. I then used stainless steel bolts and nuts, the latter with nylon retaining inserts, to remount the tube, with a large washer over the glass fibre to spread the load.

It's lasted nearly a year so far with no sign of a wobble developing let alone a recurrence, but it looks as though I may have to have a go at the other side soon!

But does anyone have advice on what material is best for replacing the foam in the hull supports to avoid scratching the cat hulls?

George

George replied:

George, the best replacement is one of those roll-up foam camping mats from Millets. About ?6, tough and well-padded, available in a nice range of colours and does not soak up water. I have picked up trolleys that have carpet as the padding, but when wet they are bloody heavy!

Charles Watson replied:

Thanks to both Georges.

George S, it looks as though someone has had a go at patching my trolley, similar to the way you suggest. I'll have a go at that & see how much I can build it up, I was thinking of trying to fill the whole void with resin & mat to give the most strength & possibly even glass in a large stainless plate for super strength. I'll see how much enthusiasm wains as I try this plan !

My trolley had carpet on it & I didn't notice any particular increase in weight, so I think I'll probably replace with some more, perhaps George knows lots of people with posh shag-pile carpets !

George Stephen replied:

Charles,

I didn't quite fill the void, but close to it. I used glass matting sizes that wrapped right over from side to side. I put in enough to more than double the original thin glass fibre that went round the tube. I used a large stainless washer to spread the load, because I couldn't be sure exactly where I would drill through the new glass for the bolts. I hadn't thought of trying to embed a plate in the matting, or to place one on top while the resin hadn't set - clearly you can drill through it later "accurately". I guess that your idea would add significant strength.

I'll think about the padding - thanks, George, for the advice about avoiding the sort of carpet that might only serve to hold water. Given that you often finish so far ahead of the rest of us, and you're such a nice guy that you fetch trolleys and help drag our cats up beaches, I guess you have a lot of experience in judging trolley weights!

George S