Zip Dee problem

[pvfjr]

I can't get the stretching arms hooked, if that makes sense. It seems like the arms are either too long, or the awning fabric shrank. I don't get it. The awning seems to unroll all the way, as shown in pic.



I'm pulling the adjusting arms out to the first sawtooth type notch. The arm overshoots the pin/bolt I think it engages with too much--more than the spring will allow. This is my first time with a Zip Dee, but it seems like it should be a simple task.

 

[Christo]

1. The hooks are supposed to engage the awning axles.
2. See how the aluminum cover slat that's attached to the coach is standing straight up? It's supposed to pivot so that it sticks out horizontally -- that's why the awning is coming up short.

 

[pvfjr]

1. The hooks are supposed to engage the awning axles.

Ah ha, so the extra long bolt someone put in there is a red herring. Thanks.

It's supposed to pivot so that it sticks out horizontally

I'd been wondering about that. I wasn't sure if this range of motion limitation was designed in, or if it's stuck. Hmm, I hope that doesn't take too much convincing to free up. Could be a pain.

 

[pvfjr]

Looking at that joint, I don't think that first segment is supposed to lay down flat. It has movement and isn't bound up, it just bottoms out in that position. Looks like it's designed that way.


On the forward end, there also isn't room on the axle for the hook. It seems like there used to be even less room than there is now. The housing seems a bit chewed up.



On the aft end, I can get the hook to engage on the axle, but I'm far from the first sawtooth notch on the detent pin. If I put the pin in the first notch, then the hook is quite a ways past the axle.

 

[pvfjr]

Hmm, my awning rail doesn't look at all like what's in the Zip Dee install instructions on the bdub site:




Even stranger, the manual shows this "Flex Key Assembly" coupling the roller assembly to the awning rail. I don't seem to have that. What gives? Someone monkey with this thing? Or are these different generations of products?

 

[Christo]

I'm not at my coach to take comparison photos but I'll post some from my archive. I'm sure there are plenty on gmcmhphotos.com, too. Your setup does appear rather, er, PO'ed. The alignment of that front arm looks way off. And what's with the electrical connections?

You keep mentioning "sawtooth notch" -- I don't have anything like that on my awning and would be interested in seeing what you're talking about.

One interesting thing about your setup is that it avoids interference between the fabric and the door. Most GMCs with ZipDees have a roller on the left (looking at the outside) top corner because without it the door scrapes the fabric. I stick a prop between the slats and the drip rail to further increase clearance. That said, there's quite a bit of pressure on your setup when the awning is deployed.

 

[ScottC]

It is defiantly that top mount, mine lays flat and cover goes strait out.

 

[LQQKatJon]

oh boy.... I think I know your issue. I had the same thing.

the first zip dee's, that came out had an aluminum extrusion hinge. then sometime in like 1990, they switched to the "flex track" that you see now.

they no longer supply that aluminum extrusion hinge, and in order to fix your problem, you need a full slat, and a "flex track" hinge. the "flex track" is the fabric hinge.

so you would remove that 1st slat, and replace it with the modern one. I can try to get some photos tonight.. the one you need, has basically the same round extrusion end on the coach side like the awning rail does.

I bought what I needed right from Zip dee, but shipping was stupid because the slat is 18' long. I suckered one of my buddies to "swing by" the zip dee location in Chicago, and saved on shipping.

 

[LQQKatJon]

It is defiantly that top mount, mine lays flat and cover goes strait out.

that is a photo of the extrusion that they used in the 80's for the hinge.

 

[LQQKatJon]

I'm not at my coach to take comparison photos but I'll post some from my archive. I'm sure there are plenty on gmcmhphotos.com, too. Your setup does appear rather, er, PO'ed. The alignment of that front arm looks way off. And what's with the electrical connections?

You keep mentioning "sawtooth notch" -- I don't have anything like that on my awning and would be interested in seeing what you're talking about.

One interesting thing about your setup is that it avoids interference between the fabric and the door. Most GMCs with ZipDees have a roller on the left (looking at the outside) top corner because without it the door scrapes the fabric. I stick a prop between the slats and the drip rail to further increase clearance. That said, there's quite a bit of pressure on your setup when the awning is deployed.

View attachment 9042
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Christo- you probably don't notice the "saw tooth" notch. on the rafter arm, on the ridged part that goes into the smooth square part, there is notches that look like a "saw" that is what that pin locks into to hold tension outwards. it is inside the shiny square tube, so unless you pull the rafter arm apart, you will not see it.

 

[LQQKatJon]

Paul,

I just was able to see a better photo of what you have going on there. It looks like you have that aluminum extrusion hinge somehow screwed or mounted to the coach. that is strange.

I think you need to pull that off and get an "awning rail" and that might fix what is going on there.

Most RV places can get or should have the basic "awning rail" that is pop riveted to the gmc roof above the drip rails. use steel shanked, closed end alumimum rivets, with a air or heavy rivet gun, and it will not leak.

AP Products 021-50803-8 RV Awning Rail - Non-Insert - 8 Ft. - Mill

AP Products 021-50803-8 Aluminum Standard Awning Rail (Mill). This is a replacement aluminum trim molding for the exterior of your RV. Commonly used to cover of seams of the RV. This trim molding doesn't allow for a vinyl screw cover, so the screws will be visible after installation.

pantherrvproducts.com

then that aluminum extrusion that almost looks to be screwed down to your roof, should slide into that awning rail.

 

[ScottC]

that is a photo of the extrusion that they used in the 80's for the hinge.

I know mine is an older unit, when I order parts its is the pre-1989, the first picture with the cover shows the "Flex Key" that slides into the awning rail on the coach to connect the 2 pieces together. Makes life much easier for install. I will eventually run to Chicago and pick up one slat, mine is split at one end where fabric connects.

 

[pvfjr]

You keep mentioning "sawtooth notch"

I wasn't sure what the terminology was before reading through the manual. It's the ratchet teeth on the rafter arms I was referring to.

Thanks for the pics! One thing I was able to verify, is I have two left hooks! So strange. The mysteries abound with this one. I also noticed one of the brackets was homemade! I'm not sure what's going on here.



The wires are just for an LED strip that was set up on the inside of the aluminum slats. Thankfully it doesn't seem to be in the way.

I also noticed it doesn't roll up very tight, and you can still see the fabric.

It almost looks like the lower brackets were installed too low, and the arms don't push the roller up high enough. I'm leaning toward the following theory: I think this is an older awning that was salvaged off another coach, and the fabrics were updated. The fabrics can't be original or as old as the awning itself, since it matches the non-original paint scheme on my coach. They do look like legit Zip Dee fabrics though. For the window awning, it also has the aluminum slat that "stands up" instead of laying down. I do like the idea of it providing more clearance at the door (I still have a roller wheel on the door, and it's still necessary).

A friend of mine also noticed the fabric is riveted onto the roller with bit of a twist on one end--the end where the rafter arm seems far too long. There may be something to gain by straightening that out.

 

[Christo]

I wasn't sure what the terminology was before reading through the manual. It's the ratchet teeth on the rafter arms I was referring to.

Thanks for the pics! One thing I was able to verify, is I have two left hooks! So strange. The mysteries abound with this one. I also noticed one of the brackets was homemade! I'm not sure what's going on here.

The wires are just for an LED strip that was set up on the inside of the aluminum slats. Thankfully it doesn't seem to be in the way.

I also noticed it doesn't roll up very tight, and you can still see the fabric. It almost looks like the lower brackets were installed too low, and the arms don't push the roller up high enough. I'm leaning toward the following theory: I think this is an older awning that was salvaged off another coach, and the fabrics were updated. The fabrics can't be original or as old as the awning itself, since it matches the non-original paint scheme on my coach. They do look like legit Zip Dee fabrics though. For the window awning, it also has the aluminum slat that "stands up" instead of laying down. I do like the idea of it providing more clearance at the door (I still have a roller wheel on the door, and it's still necessary).

A friend of mine also noticed the fabric is riveted onto the roller with bit of a twist on one end--the end where the rafter arm seems far too long. There may be something to gain by straightening that out.

I'm told that the Zip Dee folks are very helpful. If you need parts you might consider giving them a shout.