Test-fitted a custom jacking bracket to Baby Bailey. We're off on a North Island tour next month, and if we get a flat, none of my four mechanical screw bottle jacks are likely to fit under the chassis.
Answer: a beefed-up L bracket, fitted onto the existing AL-KO chassis which has as-manufactured 12mm holes at 55mm vertical centres just behind the wheels. Standard Bunnings 4.5mm stock bracket, with 12mm holes at 50mm centres is the starting point. The top of the L is about 15mm shy of the floor, right at the top of the chassis. Have to use existing AL-KO holes, drilling new ones is verboten....
Beefed up the bracket by welding two gussets - one each side of the L - to ensure it will take the strain. Plus a drill-mill extension of the bottom hole, to fit the 55mm centres. Neighbour has a MIG welder, drill mill, lathe and power hacksaw....works as an aircraft engineer - useful.
Test-fitted to ensure all jacks work in the bracket, and that dimensions allow plenty of room for a 200mm square chunk of 50mm wood underneath (Sod's Law - the flat would happen on a soft shoulder, so a load-spreading pad has to be allowed for). All good.
Brackets off now for painting (rust-proofing -phosphoric acid etch, paint, final grey spray coat) over the next week. Will be attached via M12x35mm bolts with milled-off heads to minimise protrusion. Will post photos of the finished product in a week or so.
Wayne and Madeleine
Baby Bailey 400/2 'van, Hyundai Santa Fe (CM) CRDi tug.