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  Trailer Brakes: Conversion to Electric-Over-Hydraulic

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Author Topic:   Trailer Brakes: Conversion to Electric-Over-Hydraulic
russellbailey posted 02-14-2012 08:47 AM ET (US)   Profile for russellbailey   Send Email to russellbailey  
I pull a 1984 Outrage 25 with twin Optimax 150s on a Continental 10k galvanized trailer - loaded it is about 7,500 lb depending on fuel and gear. Yesterday I picked it up after switching from the Dico 10 surge brake actuator to a Titan Brakerite SD electric-over-hydraulic (EOH) actuator. I had replaced all the brakes/lines about 18 months ago with Kodiak silver cad, so the back end is essentially new (discs on all 4 wheels).

The difference in control and sensitivity with the EOH actuator is dramatic. I pull with a 2012 Suburban 1500 now (just replaced a 1998 Ford Expedition as the tow vehicle).

I had the switch done at a nearby trailer shop - 2.5 hours labor. I also used Pacific Trailers custom mount for the Titan Brakerite, which mounts all the parts on a pre-drilled galvanized post. After that, I drove it to where I store it, which was about 45 miles through large hills, with some twisty steep roads part of the way.

Total cost was about as follows
Titan Brakerite SD - $660
Buyers 2.5" coupler - $85
Breakaway batteries - $70
Pacific mounting post - $100
Tekonsha controller - $130
Installation - $180 with parts

I could have re-used a welded Dico10 coupler, but the new coupler is much cleaner with a lower profile and the old coupler was quite worn.

So, all in was about $1300 - not inexpensive, but the difference in control over just surge brakes is dramatic - for me it is worth the difference. I realize the load I pull is at the upper end of trailerable Boston Whaler sizes - you probably would not notice the difference so much with a light boat like an Outrage 18. I also store the boat on the trailer and thus trailer it and launch every use, so the trailer does get a good bit of use.

I got most of my parts from Eastern Marine, who was very helpful in the process.

conch posted 02-14-2012 10:17 AM ET (US)     Profile for conch  Send Email to conch     
Are the brake lines rubber or metal? I am due to make this switch myself soon on a triple axel trailer.Sounds like it is a great upgrade.
Chuck
jimh posted 02-14-2012 12:50 PM ET (US)     Profile for jimh  Send Email to jimh     
Tell more about the hitch coupler you used to replace the DICO 10 coupler.
russellbailey posted 02-14-2012 01:20 PM ET (US)     Profile for russellbailey  Send Email to russellbailey     
conch, most of the lines are metal. There are a few short 12" - 18" rubber pieces.

jimh, I have this coupler. I mistyped earlier when I said 2.5" - I meant 2 5/16".
http://www.easternmarine.com/3-channel-hd-straight-tongue-trailer-coupler-91562
The person at Eastern Marine recommended it when I was looking for a Bulldog-type 2 5/16 ball coupler. It is very sturdy with most of it being cast. The "catch" is spring loaded, so as you drop the trailer on the ball the catch retracts and then pops back - with the pin in the catch can't retract. I think 2 of the 3 holes directly fit the Dico10 holes - the 3rd may have also.

jimh posted 02-14-2012 01:57 PM ET (US)     Profile for jimh  Send Email to jimh     
Thank you for the further details about the 2-5/16-inch ball diameter hitch coupler. I have a DICO Model 6 which has also a 2-5/16-inch ball diameter hitch. When I was looking at replacement with electric brakes, I was having trouble finding any suitable hitch coupler without a surge brake actuator. Your choice looks like a good one, as it appears to be able to be bolted right onto the tongue without modification.
jimh posted 02-15-2012 08:50 AM ET (US)     Profile for jimh  Send Email to jimh     
I find your report interesting because you accomplished the change in two steps. First you overhauled the trailer with new brakes, then you changed the brake actuator to electric control from surge control. This two-step process gave you the opportunity to experience the effect of the brake controller change separately from the brake overhaul. Your endorsement of the electric control is therefore more significant for me.
russellbailey posted 02-15-2012 11:26 AM ET (US)     Profile for russellbailey  Send Email to russellbailey     
In fairness to the old surge actuator, it was quite worn and in need of replacement. I have towed, for example, a U-Haul car hauler with surge brakes with a 5,000 lb car (about 7,000 lb total load) and found those brakes more effective than the setup on my boat trailer. So, if I had a new surge actuator the difference would have been less noticeable.

Still, you get many more control options with EOH. On this first tow I had to turn down the power, as it would lock up the trailer wheels at first with the controller on the default 6.0 volt setting. After adjusting as Tekonsha recommended I ended up closer to 4.5 volts to get the trailer to the threshold of wheel lockup.

Beyond just more sensitivity, here are other things I like about the setup so far.

1. The Tekonsha P3 has a "boost" feature, where when you first tap the vehicle brakes, the controller immmediately applies about 25%, 50%, or 75% of the maximum voltage to the brake controller. The boost feature lets the trailer effectively lead the braking of the vehicle slightly, whereas with surge the vehicle must first slow to activate the trailer brakes. I ended up on the first level of boost (B1).
2. You can separately manually activate the trailer brakes via a switch, such as you might if the trailer had slight instability.
3. The brakes work backing down a hill, so on a steep ramp you don't end up having your front vehicle brakes lock up and have to rely on your weaker rear vehicle brakes.
4. There is no problem using sway control. The sway control (Equalizer) that I had worked so-so with surge brakes. With the EOH there is no interference. I used the sway/weight distributing hitch with the Expedition. I might not with the Suburban as it handles the weight fine, but I think I'd still like the sway control as an added margin of safety for longer tows.

Time will tell how durable the system is. I got the impression talking with Pacific Trailers (who made the custom post) that a large number of their bigger trailers are equipped with this setup.

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