The new parts arrived within a week from Zip Dee.
The existing flex key on the coach is coming apart after 31 years. The new flex key comes with instructions and two short pieces of flex key material crimped into 4" long pieces of aluminum cover. These are used to hold the rest of the patio awning in place while sliding the old flex key and top aluminum piece out so reassembly can be done on the ground. The flex key is crimped in place about every 6" so I bought a cheap 10" vise grips and altered the moving jaw with my 4" disc grinder to match the pic Zip Dee sent.
Once the assembled parts are down they are separated and the flex key is replaced and crimped.
The new return spring (PT#201100) is a bit different than our old one. As I recall from the last time I took the old spring out about 7 years ago, the spring wire cross section was rectangular. The spring had "climbed" over itself so efficiency/force was lost. I would have to help the awning closed and it was never tightly coiled.
The new spring wire is a round cross section and quite similar to the torsion spring design used on overhead garage doors. Should work much better.
Now I just have to wait until we get the coach home--about two weeks.
2 years ago I replaced all my flex keys as well as my fabric. it wasn't difficult but I wouldn't want to have to do it again if I didn't have to. Zip dee sells a special tool to crimp an uncrimp the soft aluminum. It's basically some grip pliers with a what looks like a channel grinded into it or something. I didn't buy it, wish I had. Think it would have made it a little bit easier to do. Sewing the new awnings was an experience in itself. I had a whole lot of sunbrella plus fabric left over from a previous boat project and with that I made all the smaller awnings over the windows. I use gore thread which should last a lifetime. I sewed it up with a sailrite sewing machine. The machine that I had malfunctioned and I had to get a different one. But the heavy duty machine went through multiple layers of sunbrella like it was nothing. I learned a lot about sewing in that job. Taking the awnings off requires more than one person. The large patio awning it is best to have three people, and two ladders. Make sure all of the crimps are removed from the coach before you pull them out it will make it a whole lot easier. Also clean the channel as best as you can and spray some silicone lubricant in the channel. That helps a lot too. Once the awnings are completely off, clean the channel out really really well and spray again with silicone lubricant prior to putting it back in again.
Good luck with your job and let's see some pictures when it's all done!
I replaced my flex keys a few weeks ago. They were coming apart after only 21 years. At that rate I may have to replace them again when I am well into my '90s. At that time I will probably hire someone to do the job.
I did the window awnings by myself with only one ladder. It is not a difficult job, just takes a little time and consideration. After careful consideration, I decided replacing the patio awning flex key will require at least two people. As Bob says, be sure all crimps are well open before you try to pull the old flex key and primary slat out.
Richard
What is the flex key ?
Any pics?
The flex key is the piece of fabric with two plastic round pieces that holds your patio awning cover to the slotted rail on your coach.
Go to Zip Dee.com and under parts you can see the different components.
YAHOO!!!!!!!!!!!! TODAY AT 4:00 PM we head up to get the coach out of storage and bring it home!!
Here is a post I made a few years ago when I replaced mine - some pictures
ZipDee Awning Repair (Flex Key Replacement) (https://www.foreforums.com/index.php?topic=29253.0)
Not a bad job
I noticed on a friends GV no flex key, had an aluminum slat to the awning rail.
Well, got the coach home and then took out the Isuzu taillight internals.
Completely hardwired them and put LED lights in them. Thoroughly tested them with my battery charger then Shoe Gooed the wires in place. Tomorrow I will put them in the coach.
This means I now have two (2) complete sets of Isuzu internals.
Any bids on the extra set? (minus the LED lights, of course)
It has not been a good day.
Got my reworked passenger tailight internal in O.K. Driver's side I was trying too hard to get the internal in place and broke one of the brake/run LEDs off. So-o-o- got to order more 1157s LEDs.
Decide to replace the spring on the patio awning. Real tug of war for some reason. Finally got the old one out. Spring is rectangular shape wire. New spring is round wire. Old spring has climbed up & over itself so was not functioning correctly.
Anyway, installed the spring and started setting toe coil tension. Got up to my 18th turn and something inside let go. One hell of a buzzing and rattling!! Then no resistance at all. So, after drilling out all the rivets the DW and I pulled the tube out of the awning fabric.
Seems that the three lobe end of the spring assembly tore off the (4) 5/32" diameter stainless steel rivets that interact with the lobes.
Also, the pewter locking lever on the front end also broke 1/2 of the awning brake rod pull eye.
Today I measured the new spring setup, from the flange to the three lobe end that engages the four 5/32 diameter stainless pop rivets.
New spring to end is 49-3/8"
First pop rivet in the tube is 49-1/4".
So this means the new spring lobe was only engaging one 5/32" diameter pop rivet!! And there were four pop rivets along the axis of the tube and 1/4" apart.
I am going to have to shift the pop rivet locations in order to get more contact.
Did get the new flex key installed. Took one 78 year old guy and one 76 year old woman to do it. Me with the new hip and Mary with the bionic right knee, and two ladders.
Sorry your having these issues. You'll get it sorted and have just that much more knowledge.
It was a real PITA, just because the rivets weren't in the proper relationship to the spring, we had to take ALL the rivets out and get the tube out of the fabric. (I ought to back charge Zip Dee)
When the spring unwound I figured something broke inside the tube, but when I got the tube out I immediately understood the function of the rivets so I checked location and verified that the rivets were in the wrong location for the new spring. I intend to add a couple more rivets to insure that the interface will be much better.
The flex key was a different matter entirely. Dirt and crud over the years had packed in. I used a can of dry silicone spray to help reduce the friction. Once the top slat and key were off the coach I found that the key wasn't crimped in place. Instead there were two tiny screws near each end holding the key in place. I cleaned the groove, slid in the new key, replaced the screws and crimped the mat'l every 16"-20".
Turned out I didn't need the vice grips I purchased and altered to open the crimps Zip Dee said were there.
We were quite tired and sore when we got done, but, it had to be done. And now we know things are right (and new) and our knowledge base has increased just a little bit.
Nitehawk
I had to replace the spring in a window awning. I found that the number of turns that zipdee recommended was a lot tighter than all my other awnings so I backed off 3 turns to match the others. I figured that everything on the awnings are old and weathered and I didn't want to put any stress on the old parts, I do have the latches that keep the awnings from blowing out while traveling down the road.
Just my two cents
Some years ago, I replaced the driver side 3 awning's flex key, following the instructions, using the provided holders, removing them from the coach and doing the work on the bench. Used ladders and a rolling work stand, on smooth concrete warehouse floors.
Move forward to this year, and it was time to do the passenger 3, (5', 5' and 10') plus the big 22' awning. I was able to loosen the old flex key crimps, and then tied/stitched the new flex key to the old end, and just sort of pulled the old out as it pulled the new flex slid in. So much easier and less work. It even worked on the big awning, so I never dealt with the weight or length of the metal covers.
My reasoning was, that it was like threading a sail into the mast track or jib twin stay, or the boom. I did not need to take the mast or boom off the boat, back then.
Yesterday evening the DW came in to our living room carrying two Mike's Hard Lemonade. She said it was to celebrate.
I thought it was because we got the patio awning back together on the coach, and working. Her reply was that it was because it was two years since my lung cancer surgery.
I have been tested frequently and gotten good results each time.
Now if we can just get past this Covid-19 and my hip replacement.
Dave never though about doing that, much easier.