Hello group.
I am now the proud owner of 2 hilos, a 1994 and a 2005. both have water damage, the 94 due to my stupidity, and the 2005 is very minor due to window leaks (which have been repaired with all new butyl seals.

As I have the 94 torn completely apart I noticed the beams sag on both sides, but the side with the door is quite noticeable. I notice that even the 2005 sags and it does it on both sides because of the door on one side and a roll out on the other. I think the design is the problem. I think there should be supports directly over the area where the cables attach and there should be a beam along the entire roof. I think this would eliminate the sagging. The bottom beam would not need much strength, it would just need to support the bulb seal. to put a support beam at the top will require some revamping of the cupboards, but at this stage with the 94 I think I can do it. I think a laminated beam from plywood as the lower beam would be the strongest though I want to see the specks on OSB too.

The 2005 has a roof made from 1 inch plywood and has an aluminum frame. I think I could just add the roof support beams and correct the sag in this one.

Any thoughts?

Attached Images

hilo.JPG (37.3 KB, 45 views)

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Charlie B
1994 245 TD

Hey, Charlie. I could not agree more. The beam is discontinuous, and the 6" gap is filled using a section of 2x4 plus a section of 1/2" plywood to add up to a section 3-1/2" high x 2" wide. I replaced this wooden section with a splice that ties the whole beam together better. I ripped 2 2x4's down to 2x1, cut them 18" long, then shaved the sides for 6" at each end until they would fit into the 2x1 rectangular aluminum tubes. I made another piece 2x1-1/2x18 to go between them. I made the 1/4" plywood facing the beam continuous over the joint, then screwed and glued the whole thing. I also added spacers between the tubes every 2'. When I reassemble it I will add a section of angle to resist the cable as discussed elsewhere in this forum.

My unit has 2x2 steel knees extending from the frame to hold up the roof section when collapsed. There is one on each side of the tip-out but there also needs to be one on either side of the door.

I never thought about the Knees but on each side of a cut in a beam would be a good idea. I would think the most beam damage, other than water, would be the 4.5 constant earthquake while moving down the road. Supports on either side of doors and tipouts would be a good idea.
Charlie

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Charlie B
1994 245 TD