We just purchased a 2018 Cyclone 4005 with a Challenger ramp. Has anyone converted a ramp to serve as a patio? I've learned there is a structural difference between their ramp and patio units. The patio version has a stronger foam core and stronger substrate that is water resistant (guessing azdel). Challenger tells me the ramp I have may buckle or bow if used as a patio and will likely take on water.
Challenger was just acquired by Lippert, but they are a small group, so I was able to talk with their lead engineer. I ran a few ideas past him and he said these would probably work and I'm curious if anyone here has tried something similar.
To add strength, I was thinking of adding a layer of 1/2" or 3/4" plywood on top of ramp to distribute the weight across the full surface. I'm not sure how I would fasten the plywood. One thought is to use self-tapping screws. Another is to insert rivet nuts in the aluminum frame every 18" or 24". Drill holes in the plywood and then use machine screws to fasten into the rivet nuts.
To protect from rain, I'd paint both sides of the plywood or apply a protective coating like flex seal. I could also apply a coat to the ramp before attaching the plywood. Would anything else work better? To dress up the plywood, I was thinking of topping it with cheap outdoor carpet.
To convert the ramp to a patio, I would buy Lippert's cable system or create a homemade version ala Home Depot. The engineer said it would be OK to drill holes in the aluminum frame that borders the patio to accommodate 2 bolts to support the cable brackets. I have the metal flange in the top of the trailer frame for the other end of the cables. I also found patio jacks on amazon that sit on the ground and have wide rubber feet to support the underside of the door. I'm curious if anyone is using them.
To add a fence or rail kit...the best idea I've come up with is a portable pet gate with panels that connect with a rod through a hinge on each end of the panel. My wife would like something a little more elegant....but the Lippert rail kit is 2k. I don't need the rail system to support the weight of people leaning on it, I just need it to keep our small dogs from jumping ship.
For the door, I was going to purchase a sliding patio door from HD and frame it with 2x4s. I'm guessing others have tried this, so if you have suggestions or resources, I'd greatly appreciate it.
The alternative to my homegrown solution sounds very expensive. It would be easier to purchase a Challenger patio door since I've learned Lippert places the springs in different locations. A new door (from either company) is just over 2k, and the patio rail kit and the 3 season door also adds about 2k each and shipping for all three is close to 2k. After 6 years of saving and scrimping, we purchased this Cyclone less than a month ago. It was a dream come true for us. I knew it didn't have the rail system or 3 season door, but I honestly thought a call to my dealer, Lippert, or etrailer would quickly solve that problem. That was a major oversight on my part. So, I'm hoping that my new friends on the forum have good news for me. Has anyone successfully upfitted a ramp to serve as a patio? I only know enough to be dangerous with projects like this so I'm seeking advice from the voice of experience and I'm open to all suggestions
Challenger was just acquired by Lippert, but they are a small group, so I was able to talk with their lead engineer. I ran a few ideas past him and he said these would probably work and I'm curious if anyone here has tried something similar.
To add strength, I was thinking of adding a layer of 1/2" or 3/4" plywood on top of ramp to distribute the weight across the full surface. I'm not sure how I would fasten the plywood. One thought is to use self-tapping screws. Another is to insert rivet nuts in the aluminum frame every 18" or 24". Drill holes in the plywood and then use machine screws to fasten into the rivet nuts.
To protect from rain, I'd paint both sides of the plywood or apply a protective coating like flex seal. I could also apply a coat to the ramp before attaching the plywood. Would anything else work better? To dress up the plywood, I was thinking of topping it with cheap outdoor carpet.
To convert the ramp to a patio, I would buy Lippert's cable system or create a homemade version ala Home Depot. The engineer said it would be OK to drill holes in the aluminum frame that borders the patio to accommodate 2 bolts to support the cable brackets. I have the metal flange in the top of the trailer frame for the other end of the cables. I also found patio jacks on amazon that sit on the ground and have wide rubber feet to support the underside of the door. I'm curious if anyone is using them.
To add a fence or rail kit...the best idea I've come up with is a portable pet gate with panels that connect with a rod through a hinge on each end of the panel. My wife would like something a little more elegant....but the Lippert rail kit is 2k. I don't need the rail system to support the weight of people leaning on it, I just need it to keep our small dogs from jumping ship.
For the door, I was going to purchase a sliding patio door from HD and frame it with 2x4s. I'm guessing others have tried this, so if you have suggestions or resources, I'd greatly appreciate it.
The alternative to my homegrown solution sounds very expensive. It would be easier to purchase a Challenger patio door since I've learned Lippert places the springs in different locations. A new door (from either company) is just over 2k, and the patio rail kit and the 3 season door also adds about 2k each and shipping for all three is close to 2k. After 6 years of saving and scrimping, we purchased this Cyclone less than a month ago. It was a dream come true for us. I knew it didn't have the rail system or 3 season door, but I honestly thought a call to my dealer, Lippert, or etrailer would quickly solve that problem. That was a major oversight on my part. So, I'm hoping that my new friends on the forum have good news for me. Has anyone successfully upfitted a ramp to serve as a patio? I only know enough to be dangerous with projects like this so I'm seeking advice from the voice of experience and I'm open to all suggestions
