Doubled rear cross frame to increase hitch tongue weight. OEM frame is 1/8” thin!

[EveryDayBronco]

OEM tongue weight is 350 lbs and I want to carry my exc-f on the hitch and since the load would be farther I doubled the rear frame to beef up the hitch tongue capacity.

Super tedious work and had to modify the muffler location to make space for a second cross frame.

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[mmbretts]

I've not had any issues bith a bike carrier, but I respect the belt and suspenders approach. Hauled this bike 7hr without issue or any signs of structural issue.

Does your setup tie the new crossmsmber to the hitch at all or is it just tying the fram rails together?

 

[EveryDayBronco]

I've not had any issues bith a bike carrier, but I respect the belt and suspenders approach. Hauled this bike 7hr without issue or any signs of structural issue.

Does your setup tie the new crossmsmber to the hitch at all or is it just tying the fram rails together?

You're scaring me!

The cross member is thin box section, and tongue weight is rated for 350 lbs at the ball which is around 8" from the pin.

The carrier extends another 24" farther out which put approx. 3x the moment on the cross member.

IOW 300 lbs of bike + carrier that far back works out to around 900 lbs on a hitch that is rated for 350 lbs.

Now that you've tested it, how does it handle with the weight of the bike back there?

I would check the welds here, all around and both ends.

 

[BigMeatsBronco]

OEM tongue weight is 350 lbs and I want to carry my exc-f on the hitch and since the load would be farther I doubled the rear frame to beef up the hitch tongue capacity.

Super tedious work and had to modify the muffler location to make space for a second cross frame.

Nice work, can't tell from the pictures exactly what's going on.But I would definitely tie those two together directly.At the hitch.

 

[mmbretts]

You're scaring me!

The cross member is thin box section, and tongue weight is rated for 350 lbs at the ball which is around 8" from the pin.

The carrier extends another 24" farther out which put approx. 3x the moment on the cross member.

IOW 300 lbs of bike + carrier that far back works out to around 900 lbs on a hitch that is rated for 350 lbs.

Now that you've tested it, how does it handle with the weight of the bike back there?

I would check the welds here, all around and both ends.

No signs of deflection or fatigue. Minimal concern and I'd do it again without hesitation.

Handling is fine. Little more sway and the headlights were high terrorizing traffic, but I'm not expecting sportscar handling or one-ton dually carrying capacity.

I'm not sure since mine's removed, but the spare tire might give you grief. Not much room between bike and tailgate, at least on my carrier.

 

[EveryDayBronco]

Nice work, can't tell from the pictures exactly what's going on.But I would definitely tie those two together directly.At the hitch.

The new cross member is 2.5x2.5x.25" tube steel and is bolted to the back of the hitch with the four 1/2" bolts. Contact area is 9.75"x 2" with bolts torqued tight.

Welding the new tube steel to the hitch would be next level for strength but the end brackets, which you can see, are as strong as I could practically design, and out of the entire system, they are the weak points. So, welding my new tube steel to the hitch wouldn't make the whole thing any better.

I would not weld anything to the bronco frame. If it was old, I might but not now.

 

[EveryDayBronco]

No signs of deflection or fatigue. Minimal concern and I'd do it again without hesitation.

Handling is fine. Little more sway and the headlights were high terrorizing traffic, but I'm not expecting sportscar handling or one-ton dually carrying capacity.

I'm not sure since mine's removed, but the spare tire might give you grief. Not much room between bike and tailgate, at least on my carrier.

Not having the spare tire puts you about 8" closer which is not as bad but you're still overloading hitch by something like 2x.

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