Broken Daystar Airbag Cradle/Cup

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Broken Daystar Airbag Cradle/Cup

Post by Ducky's Dad » Fri Jul 22, 2016 9:03 pm

Had the truck on the lift today, and found that the right side Daystar cradle under my newish Firestone Ride Rite bags has fractured and broken away. The outer third of the cup is just gone, looks like a clean fracture and it just fell off. These cups went on about eleven months ago, at the same time that I installed the Carli rear spring packs and the Firestone air bags. No other damage on the right side, and left side cradle appears OK.

Anyone else experienced Daystar cradle failure?

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Re: Broken Daystar Airbag Cradle/Cup

Post by RustyPW » Fri Jul 22, 2016 10:15 pm

You might be the first.
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Mods to the PW; Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper , PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli G2 Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, Carli Control Arms, Thuren 3" SoftRide Springs, Thuren Rear Shackles, MagnaFlow Muffler, Crown Stainless Brake Lines, MORE STUFF COMIN'.

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Re: Broken Daystar Airbag Cradle/Cup

Post by TwinStick » Fri Jul 22, 2016 11:24 pm

:idea: Take the good one off & take it to a fabricator & have the new one made with stronger, thicker steel. Maybe even a slightly larger dia circle, to keep this fromm happening again.Yup, it's gonna cost ya, but hard to put a price on peace of mind in the remote back country.
In WNY State. 2008 Red QC PW G56. No lift yet, stock size tires. It pulls an 18' 2016 Starcraft AR One Extreme, 3500 lbs.
Load Pro 35 helper springs. 2015 A.R.E. MX Series custom cap. PCP front diff cover protector. Mag-Hytec 6 qt rear diff cover. K&N replacement air filter only. Dual grounded throttle body. Winch TPC bypass. Fab Four rear bumper. DURA BAK lined rocker protection. And a bunch of new front end stuff.

G-56 Gear ratios: 1st) 6.29:1 2nd) 3.48:1 3rd) 2.10:1 4th) 1.38:1 5th) 1.0:1 6th) 0.79:1 Rev 6.29:1 --- = 78.01613:1 Crawl Ratio
-------------------------5.94:1--------3.28:1-------1.98:1-------1.31:1-------1.0:1-------0.74:1-----5.42:1 ---- = 73.675:1
545RFE----------------3.0:1---------1.67:1--------1.0:1--------0.75:1-------0.67:1------------------3.0:1 -------=37.21:1

2013+ 32.47 crawl ratio...............Can you see the trend ??????????????

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Re: Broken Daystar Airbag Cradle/Cup

Post by Ducky's Dad » Fri Jul 22, 2016 11:48 pm

have the new one made with stronger, thicker steel.
They are plastic.

http://daystarweb.com/productdetail.php?productID=1232

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Re: Broken Daystar Airbag Cradle/Cup

Post by TommyG » Sat Jul 23, 2016 9:26 am

TwinStick wrote::idea: Take the good one off & take it to a fabricator & have the new one made with stronger, thicker steel. Maybe even a slightly larger dia circle, to keep this fromm happening again.Yup, it's gonna cost ya, but hard to put a price on peace of mind in the remote back country.
This isn't a bad idea if you know someone who would machine it out of delrin. I wonder if that would hold up any better.
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Re: Broken Daystar Airbag Cradle/Cup

Post by TwinStick » Sun Jul 24, 2016 9:22 am

1) Why the hell would anyone use plastic for that application, is beyond me.
2) I would have them made out of 1/4" steel, use a piece of rubber in the bottom of cradle to keep things quiet & hold it in place w/some construction glue.
3) Done, never to worry about it again.


Power Wagon owners worry about stuff like that. We don't want a failure in the middle of nowhere. Daystar gets an EPIC FAIL in my book for this. :wtf:
In WNY State. 2008 Red QC PW G56. No lift yet, stock size tires. It pulls an 18' 2016 Starcraft AR One Extreme, 3500 lbs.
Load Pro 35 helper springs. 2015 A.R.E. MX Series custom cap. PCP front diff cover protector. Mag-Hytec 6 qt rear diff cover. K&N replacement air filter only. Dual grounded throttle body. Winch TPC bypass. Fab Four rear bumper. DURA BAK lined rocker protection. And a bunch of new front end stuff.

G-56 Gear ratios: 1st) 6.29:1 2nd) 3.48:1 3rd) 2.10:1 4th) 1.38:1 5th) 1.0:1 6th) 0.79:1 Rev 6.29:1 --- = 78.01613:1 Crawl Ratio
-------------------------5.94:1--------3.28:1-------1.98:1-------1.31:1-------1.0:1-------0.74:1-----5.42:1 ---- = 73.675:1
545RFE----------------3.0:1---------1.67:1--------1.0:1--------0.75:1-------0.67:1------------------3.0:1 -------=37.21:1

2013+ 32.47 crawl ratio...............Can you see the trend ??????????????

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Re: Broken Daystar Airbag Cradle/Cup

Post by nts007 » Sun Jul 24, 2016 10:29 am

I've avoided the cradles for my expectations of this happening. Slamming two parts together will eventually break something. Wether cradle or air bag. Honestly it cost me less to find and modify longer air bags using the Firestone mounts. That is my suggestion if you need air bags. Find a good local highway truck supplier. In my build thread is some part numbers.
08 ctd--mini max--thuren 3" coils and LT Leaves--4.56 gears and lockers in pw axles--some lights--afe intake system--bd super b turbo--Banks w/m Injection--Dynatrac Balljoints--king 2.5"s--37" Hankook Dynapro MT--DOR Long arms--Custom emf track bar--Manual T-case swap--Full PW Under armor--PSC Hydro Assist and so much more

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Re: Broken Daystar Airbag Cradle/Cup

Post by Ducky's Dad » Sun Jul 24, 2016 12:20 pm

I'm going to call Daystar tomorrow to see what they have to say about this, see if there is any history. With luck, they may send me a new piece since it's been less than a year and maybe 6M since they were installed. I'm just guessing that the break occurred on the same run that bent my roof rack (excess weight from a full water tank on the rack). That was about 60mph through a pretty raggedy field in AZ. Building a smaller water tank in the next couple of weeks to reduce weight.

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Re: Broken Daystar Airbag Cradle/Cup

Post by RustyPW » Sun Jul 24, 2016 4:45 pm

I'll keep my Carli air bags. :lol:
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Mods to the PW; Nerffed Mopar RockRails, Wheel Well Liners, Bushwacker Pocket Fender Flairs, Garvmin dezl 560LMT GPS, Power Wagon Winch Kit, Line X Ultra Bed Liner, PIAA Headlight Bulbs, PIAA 580 Driving Lights (135 watt), PIAA 520 Fog Lights (135 watt), PIAA 520 ATP Off-Road Lights (135 watt), Locker Bypass, Modifed Rockcrusher Diff Covers, Mopar Utility Bed Rails and Tool Box, Warn Winch Wireless Remote Control, "el-cheapo" Inclinometer, Airaid CAI, Winch TPS Bypass, 35" Toyo's, Mopar Spare Tire Lock, 'T' Steering Linkage, Modifed PSC Steering Brace, P3 Brake Controller, Modifed Fusion "mall crawler" rear bumper , PIAA 1500 Back-Up Lights, 1Ton HEMI Tranny Cooler, Leer 100XR Bed Cap, Factory Tow Mirrors, CenterLine Rims 17x9-5.25 BS, Mag-Hytec Tranny Pan, AutoMeter Gauges, PSC Extreme Hydro Assist Steering, Carli G2 Track Bar, Carli Ball-Joints, Dynatrac FreeSpin Hubs, Snorkel, RCV Axles, EBC Pads & Rotors, Aluminess Front Bumper, BIG Pul-Pal, 60" Extreme Hi-lift Jack, and more riggin' equipment, Carli Long Travel Air Bags, Bilstein 7100 Shocks - Carli Valving, Carli Control Arms, Thuren 3" SoftRide Springs, Thuren Rear Shackles, MagnaFlow Muffler, Crown Stainless Brake Lines, MORE STUFF COMIN'.

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Re: Broken Daystar Airbag Cradle/Cup

Post by Ducky's Dad » Mon Jul 25, 2016 11:37 pm

Called Daystar this morning, and they thought I was the guy who emailed them on Saturday. Turns out a guy in Canada had the same problem I had and we reported it within a couple days of each other. Daystar is sending me a fresh pair of cradles, no receipt or requirement to return the broken part. Tech support said it must have been a bad run of parts, since it's not a common problem. Good customer service, I think I'm still a happy camper. But I have to wrench under the truck again.

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Re: Broken Daystar Airbag Cradle/Cup

Post by Reloaderguy » Tue Jul 26, 2016 12:44 am

Canadians break everything. :lol:
Best Year Power Wagon

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Re: Broken Daystar Airbag Cradle/Cup

Post by TwinStick » Tue Jul 26, 2016 1:32 pm

Did you tell them to use Canukistan Plastic, so they will have no issues in the future ??? LOL :lol:

J/Kidding, no hate mail please. :lol:
In WNY State. 2008 Red QC PW G56. No lift yet, stock size tires. It pulls an 18' 2016 Starcraft AR One Extreme, 3500 lbs.
Load Pro 35 helper springs. 2015 A.R.E. MX Series custom cap. PCP front diff cover protector. Mag-Hytec 6 qt rear diff cover. K&N replacement air filter only. Dual grounded throttle body. Winch TPC bypass. Fab Four rear bumper. DURA BAK lined rocker protection. And a bunch of new front end stuff.

G-56 Gear ratios: 1st) 6.29:1 2nd) 3.48:1 3rd) 2.10:1 4th) 1.38:1 5th) 1.0:1 6th) 0.79:1 Rev 6.29:1 --- = 78.01613:1 Crawl Ratio
-------------------------5.94:1--------3.28:1-------1.98:1-------1.31:1-------1.0:1-------0.74:1-----5.42:1 ---- = 73.675:1
545RFE----------------3.0:1---------1.67:1--------1.0:1--------0.75:1-------0.67:1------------------3.0:1 -------=37.21:1

2013+ 32.47 crawl ratio...............Can you see the trend ??????????????

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Re: Broken Daystar Airbag Cradle/Cup

Post by nts007 » Tue Jul 26, 2016 10:35 pm

TwinStick wrote:Did you tell them to use Canukistan Plastic, so they will have no issues in the future ??? LOL :lol:

J/Kidding, no hate mail please. :lol:
Hate mail?? That's just acknowledgment that we make better plastic than China.
08 ctd--mini max--thuren 3" coils and LT Leaves--4.56 gears and lockers in pw axles--some lights--afe intake system--bd super b turbo--Banks w/m Injection--Dynatrac Balljoints--king 2.5"s--37" Hankook Dynapro MT--DOR Long arms--Custom emf track bar--Manual T-case swap--Full PW Under armor--PSC Hydro Assist and so much more

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Re: Broken Daystar Airbag Cradle/Cup

Post by TwinStick » Wed Jul 27, 2016 2:40 pm

:lol:

:rockon:
In WNY State. 2008 Red QC PW G56. No lift yet, stock size tires. It pulls an 18' 2016 Starcraft AR One Extreme, 3500 lbs.
Load Pro 35 helper springs. 2015 A.R.E. MX Series custom cap. PCP front diff cover protector. Mag-Hytec 6 qt rear diff cover. K&N replacement air filter only. Dual grounded throttle body. Winch TPC bypass. Fab Four rear bumper. DURA BAK lined rocker protection. And a bunch of new front end stuff.

G-56 Gear ratios: 1st) 6.29:1 2nd) 3.48:1 3rd) 2.10:1 4th) 1.38:1 5th) 1.0:1 6th) 0.79:1 Rev 6.29:1 --- = 78.01613:1 Crawl Ratio
-------------------------5.94:1--------3.28:1-------1.98:1-------1.31:1-------1.0:1-------0.74:1-----5.42:1 ---- = 73.675:1
545RFE----------------3.0:1---------1.67:1--------1.0:1--------0.75:1-------0.67:1------------------3.0:1 -------=37.21:1

2013+ 32.47 crawl ratio...............Can you see the trend ??????????????

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Re: Broken Daystar Airbag Cradle/Cup

Post by fbenross » Wed Jul 27, 2016 4:57 pm

I think everyone needs to take a deep breath. I've had my PW over 10 years now, and my Firestone air bags for 10 years. I just got back from a camping trip and after reading Duckys post today I went out and checked my Daystar cradles. They are fine-even with a ton of camper and cycle on the back. So I guess I wont go have them copied with a titanium additive 3D printer at GE...I think Daystar took care of it for Ducky the right way, and it just might have been a bad run. I've said it before here, with stock PW suspension the firestone bags are just fine. I've flexed/squished mine to the max for 10 years. And most of that w/o the daystars. Time will tell on the cradles toughness.... Ducky should have got a Raptor if he wanted to do 60 out in the boonies :D
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Re: Broken Daystar Airbag Cradle/Cup

Post by Ducky's Dad » Wed Jul 27, 2016 6:19 pm

Ducky should have got a Raptor if he wanted to do 60 out in the boonies :D
Only two problems with that:
There was no Rapturd in 2005, and...
The Rapturd is not a real truck.

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Re: Broken Daystar Airbag Cradle/Cup

Post by fbenross » Wed Jul 27, 2016 6:28 pm

Ducky's Dad wrote:
Ducky should have got a Raptor if he wanted to do 60 out in the boonies :D
Only two problems with that:
There was no Rapturd in 2005, and...
The Rapturd is not a real truck.
If I was rich, I'd have on in my HUGE garage.
Ben CW3 2/10th AIR CAV FT ORD CA. (retired)
2006 Power Wagon-6spd, rear air bags, Diff Guards:Carli F. RockCrusher R., matching rim for spare tire, removed back seat for storage----I own the following: 2005 Hallmark pop-top Camper---1970 Scout 800 4x4 w/232ci 6cyl 4spd---2006 Yamaha XT225 Dual Sport---Pictures @ https://www.flickr.com/photos/powerwagon/collections

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Re: Broken Daystar Airbag Cradle/Cup

Post by Ducky's Dad » Wed Jul 27, 2016 9:18 pm

If I were rich, I'd have Thuren or Carli just build me a go-fast Power Wagon, but I'd keep my '05 for hunting trips.

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Re: Broken Daystar Airbag Cradle/Cup

Post by fbenross » Wed Jul 27, 2016 11:33 pm

Ducky's Dad wrote:If I were rich, I'd have Thuren or Carli just build me a go-fast Power Wagon, but I'd keep my '05 for hunting trips.
It still wouldn't look or be as nice..plus I have a PW ...remember H2o is 8.3 pnds/gal :doh:
Ben CW3 2/10th AIR CAV FT ORD CA. (retired)
2006 Power Wagon-6spd, rear air bags, Diff Guards:Carli F. RockCrusher R., matching rim for spare tire, removed back seat for storage----I own the following: 2005 Hallmark pop-top Camper---1970 Scout 800 4x4 w/232ci 6cyl 4spd---2006 Yamaha XT225 Dual Sport---Pictures @ https://www.flickr.com/photos/powerwagon/collections

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Re: Broken Daystar Airbag Cradle/Cup

Post by Ducky's Dad » Wed Jul 27, 2016 11:41 pm

remember H2o is 8.3 pnds/gal
Timing is everything. I just started gluing up the new, sleeker, lighter, more aerodynamic, better looking water tank today. Ordered some heavy duty crossbars for the roof rack to carry the tank, but they arrived damaged, so waiting for a fresh shipment. The weight I save with the new water tank will be offset by the Pull-Pal RW14000 I will be schlepping around.

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Re: Broken Daystar Airbag Cradle/Cup

Post by fbenross » Wed Jul 27, 2016 11:50 pm

When I leave on a trip I have 28 gal cuz water is the limiter to boon docking for my setup. I agree with the weight trade off. That's wy I took off my rock rails. But I haven't ditched the RW14000 yet.
Ben CW3 2/10th AIR CAV FT ORD CA. (retired)
2006 Power Wagon-6spd, rear air bags, Diff Guards:Carli F. RockCrusher R., matching rim for spare tire, removed back seat for storage----I own the following: 2005 Hallmark pop-top Camper---1970 Scout 800 4x4 w/232ci 6cyl 4spd---2006 Yamaha XT225 Dual Sport---Pictures @ https://www.flickr.com/photos/powerwagon/collections

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Re: Broken Daystar Airbag Cradle/Cup

Post by Ducky's Dad » Thu Jul 28, 2016 10:11 am

I was carrying about 23+ gallons with my old setup, 18 of those on the roof rack. New rack tank will be about 12+ gallons, so about 50 pounds less water, about the same weight as the RW14000. I'll save more weight through the tank redesign because I'm eliminating nine 6" PVC fittings, and those suckers are heavy. Got carried away on the old tank because I wanted as much water as I could fit up there. Sometimes good enough is good enough.

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Re: Broken Daystar Airbag Cradle/Cup

Post by fbenross » Thu Jul 28, 2016 10:37 pm

Did you ever post any pictures of that setup ?
Ben CW3 2/10th AIR CAV FT ORD CA. (retired)
2006 Power Wagon-6spd, rear air bags, Diff Guards:Carli F. RockCrusher R., matching rim for spare tire, removed back seat for storage----I own the following: 2005 Hallmark pop-top Camper---1970 Scout 800 4x4 w/232ci 6cyl 4spd---2006 Yamaha XT225 Dual Sport---Pictures @ https://www.flickr.com/photos/powerwagon/collections

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Re: Broken Daystar Airbag Cradle/Cup

Post by Ducky's Dad » Thu Jul 28, 2016 11:49 pm

This is the old tank that I am replacing to reduce weight on the rack. This one is made up from 6" PVC Sch40 pipe, with lots of big fittings (mostly with custom cuts to get them to fit) and lots of glue joints. Capacity calculates to more than 18 gallons, and I configured it to fit fairly precisely over the projections of the Yakima rack crossbars, so that it can't move forward or backward because the bars are captured b the tees. The tank is held to the Con-Ferr basket by stainless steel U-bolts and some fabbed aluminum reinforcements. Overall length is about 6.5 feet, and it can be filled from the 4" plug in the top, or by a pressurized garden hose attached to the boiler drain at the rear. This tank is heavy even when empty, and it bent the crossbar at the rear rack tower when I drove a bit too fast over rough ground with a full tank. New tank will be a single length of 6" PVC with a screw cap at the front for cleaning and flushing, and a saddle fitting at top rear with 4" threaded plug for filling and the same boiler drain for draining or pressure filling. Overall length is 8.5 feet, about the same as the bag awning on the opposite side of the rack. Will use same U-bolts and reinforcements as old tank and capacity will probably be right at 13 gallons. New Yak bars will be the HD 86" bars cut down to fit my system, and I will probably fill the tank with wiffle softballs to control surge in the tank. The front caps facilitate the wiffle idea.
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Re: Broken Daystar Airbag Cradle/Cup

Post by fbenross » Fri Jul 29, 2016 12:46 pm

I like the whiffle ball idea. I think they should not be able to move inside the pipe to be effective.
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2006 Power Wagon-6spd, rear air bags, Diff Guards:Carli F. RockCrusher R., matching rim for spare tire, removed back seat for storage----I own the following: 2005 Hallmark pop-top Camper---1970 Scout 800 4x4 w/232ci 6cyl 4spd---2006 Yamaha XT225 Dual Sport---Pictures @ https://www.flickr.com/photos/powerwagon/collections

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