Repairing Zip Dee Awning

encantotom · 07-26-2009, 12:22 AM

hi all,

my 22' classic zip dee awning started to not work well. it ended up that the piece of canvas between the coach and the aluminum slats had sun rotted and was just ripping to the point of the awning could eventually separate from the coach in a stiff wind.

the piece that was rotted is called the "flex key" and is available from zip dee. it was almost a hundred bucks for mine shipped. it is sold by the foot and is two different diameter plastic sold tubes that have a 1" piece of heavy canvas doubled up and sewn around them. it is like a canvas hinge. they slide in the first aluminum slat cover and the mount to the coach in round slots.

it is not hard, but time consuming and takes a number of people and 2 sets of 10' high scaffolding to hold it up at each end.

you pull the awning down, then take the arms off the coach. then the tension side take the outer arm off carefully and hold onto the short arm. it has considerable tension on it and can whack you and the coach pretty hard. it is wound to the number of turns = the length of the awning in feet.

un wind it so there is no tension on it.

then we set the scaffolding at each end of the awning and set it up with the awning fully extended resting on each end of the scaffolding.

then we carefully rolled it up by hand until it was about a foot from the coach and set it on towels on the scaffolding.

then i drilled out the rivets that held the end pieces on that the arms hook into when stored. also the rivets that held the canvas flex key in.

zip dee said to slide the new flex key in as you took the old one out, but mine was too rotten. so i took a box knife and cut the flex key in half all along the coach. then carefully set the aluminum slat side of the awning to hang down.

then i just pulled the two pieces out from one end and it was out.

next my wife darlene sewed two strips of heavy upholstery vinyl onto one end of the flex key so we could use it to pull it.

then she fed it in one end, my son supported it and we leap frogged pulling the new flex key in. took about 30 minutes.

then i trimmed the ends, riveted the end pieces on to hold the flex key in (the pieces that act as the slotted holder for the arms as they store.

next i cleaned the arms and polished and lubed them so they would operate smoother, then hand rolled the awning back out, then moved the scaffolding out and set the awning on ladders, then re-tensioned it, re-installed the arms and off to the races.

i have to tell you it took me many hours and it is much easier to describe now that i have done it.

pictures to follow,

tom

zcasa · 07-26-2009, 01:06 AM

Wow, can't wait to see the pic's and the coach in Creede in a week. You are amazing what you can do to your coach. You will enjoy your Coach for many many years of wonderful service the way you have fixed it up, upgraded it and reconditioned it. It simply is beautiful. Thanks for always sharing with us your projects.

David

prairieschooner · 07-26-2009, 03:47 AM

me too, we will look at it when at Creede

encantotom · 07-26-2009, 05:46 AM

more pictures

tom

Stick Miller · 07-26-2009, 01:12 PM

I think I want to be Tom's coach in my next life.

Wally Arntzen · 07-26-2009, 03:35 PM

Great job Tom and Darlene and crew. You guys are get er done people and I love it. I feel like I'm the guy that caused you to have do it sooner than you would liked to.

encantotom · 07-26-2009, 05:38 PM

wally, no way. unless you control the suns rotting of canvas power.....

tom

tuga · 07-26-2009, 07:44 PM

Tom,

Thanks for a great post and fabulous pictures. I'm sure this will be a big help to anyone who has to replace their awning.

This is what this forum is all about: Newellies helping Newellies!

Good Post!

chockwald · 07-27-2009, 03:09 AM

I'm looking for the pictures of the sweat dripping off your face while you wrestled it into place....LOL! How hot was it while you were doing this project? Elaine and I struggled with our little 9 foot awning we added over the kitchen and bathroom windows.

encantotom · 07-27-2009, 03:50 AM

it was hot. we started about 6:15am and worked on a off during the day as we got too hot.

then finished in the early evening when the sun wasnt shining on that side of the newell.

there was plenty of sweat lost,

not sure how hot, but in the mid 100's as it has been alot cooler the last few days. it was 109 today.

trying to get my todo list done for the trip. i have a number of things i need to put back together to be able to leave

later

tom

zcasa · 08-26-2009, 04:12 PM

Hi Everyone:

I have the A and E box awnings around my Coach. They are only for shading the windows and not the mega awning over the door. I have had three occasions now, where the wind velocity extends an awning or two involuntarily while driving. I must reduce my speed quickly to 45 mph or so and they will retract. This is obviously unsettling and, at some point, will reduce the affected awning to shreds. My question is, Where do I get some security bracket to secure all awnings before hitting the road? Thanks for your assistance.

David

encantotom · 08-26-2009, 04:30 PM

on the zip dee awnings i have there is a travel latch kit you can buy from the factory to keep them from coming down in addition to the Z lock.

i have them on my big awning and then the biggest of the window awnings for the very reason you say. because my main awning came down while i was driving on the freeway one time and it was quite an experience.

so, since i dont know which exact awning you have, you should call dometic help number to ask them for the travel latch kit for your specific awning and at least get the part number so you can search online or decide to buy from them.

574-294-2511 dometic

tom

chockwald · 08-26-2009, 04:46 PM

David, another possible option is to tighten the spring in each awning. I would think that increased spring tension would keep them from extending. I have 4 of the window awnings, and have never had one of them extend while in motion. On my large patio awning I do have two Z locks.

I'll e-mail you the .pdf file with instructions on how to tighten the spring.

encantotom · 08-26-2009, 04:54 PM

clarke,

david has the dometic awnings, so not sure the zipdee tensioning instructions will apply to his.....

tom

fulltiming · 08-26-2009, 05:44 PM

David, Dometic has purchased A&E. The only instructions I have found on their site that discusses tensioning the awnings is listed below. Page 5 and 6 show retensioning.
http://www.dometic.com/FileOrganizer/1-international/Operation%20&%20Installation%20Manuals/Awnings/Sunchaser-8300-service-instructions.pdf

If your window awnings require some effort to pull down, I am not sure it would be worth the effort on an A&E. I don't see any A&E product that operates the way the ZipDee Awning Travel Lock does. There are a couple of links that might be of interest to you.

Here is one specifically for window awnings (although I am not sure how secure it would be):
http://www.sportsmansguide.com/net/c...7&kwtid=296697

Here are a couple of solutions that appears to be aimed at the main awning but might also work on a window awning.
http://www.anythingrv.com/staticpage...RV_Awning_Lock

http://www.dasplace.net/Awning/AwningFix.html

Typically the side of the window awnings makes them much less susceptible to billowing out while driving than the much larger main awnings.

encantotom · 08-26-2009, 05:52 PM

after thinking about this a bit more, i think maybe we are approaching this as engineers on how to fix the problem. instead, maybe we should EMBRACE the problem as an advantage. so, how about putting all the awnings down before driving, and using them as "lift" to decrease the weight on the tires, which we have all been saying is another problem we have.

so, with the awnings down, there will be some lift on the coach, reducing the air pressure needed for the tires, saving the cost of the air pressure multiplier, and extending the life on the tires.

besides that, it would look really cool!

that my 2 cents worth and in this case, about all it is worth!

tom

chockwald · 08-26-2009, 06:03 PM

Didn't realize they were Dometic....well, so much for that idea...LOL!

zcasa · 08-26-2009, 06:05 PM

Good info, thanks guys. I'll get to work on this project soon. I tend to lean towards Tom's suggestion and would augment my driving experience by adding some aviator shades, flight jacket, and join a frequent flyer program. Most people think I'm pretty cool already, so this will take me over the top. Thanks, Tom, impressive thinking for sure.

David

folivier · 08-26-2009, 07:00 PM

Wow, I just don't think like you guys!
I was thinking of putting a snorkel on my coach in case of severe and catastrophic coastal erosion one night.
But thinking along the way you guys do, I think I'll just keep my awnings deployed and hang balloons from them! Instant flotation!

Richard and Rhonda · 08-26-2009, 10:06 PM

Dumbo, the flying Newell.