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I want to change the coupler on my ATV trailer to 2 5/16" so I bought a new coupler. I measured the bolt holes in the trailer tongue and came up with 3" between them. I then found this coupler that had the same measurement between holes. Somehow I didn't realize the holes with 3" between them were to the front of the coupler, not the back. Consequently, the coupler will not fit on the tongue using the existing holes in the tongue.
What should I do?
1. Cut off the back of the coupler so it fits on the tongue. I suspect that the coupler metal will be quite stout and difficult to cut.
2. Drill new holes in the coupler.
3. Drill new holes in the tongue.
4. Something else?
My thought is if all you have to do is trim the coupler so the rearmost hold goes to where the bolt is now, I would trim the coupler. I suspect an angle grinder would work, however, one thing I discovered by accident is Harbor Freight has a blade that fits in a 7 1/2' circular saw that cuts metal. Sounds crazy I know, but have been using one in my shop when I am welding and it really works and saves an incredible amount of time. Instead of sawdust you get bits of metal, but as long as you don't try to horse it it as saved me a lot of work and is much easier to make a straight cut (for me) than using my angle grinder. Best about $20.00 I ever spent! I would be disinclined to drill more holes thinking lessening the amount of metal would weaken the pieces, however if you are not towing much weight that may not make much difference given I suspect that coupler is designed to handle way more weight than your ATV.
Steve, I too was a bit leery of adding more holes to either the coupler or the trailer. I have a sacrificial circular saw that I could slap a cheap cutoff blade on.
Two votes for cutting off the end of the coupler. Sounds good. Thanks guys.
I wanted to add my opinion to this quickly before you go ahead with cutting off the back of the coupler. It's hard to tell in the pictures but it looks to me like the coupler does not sit down tight onto the top of the trailer tongue when the bolts are in it. This would put additional shear stress on your bolts as more tongue weight is added.
If that is in fact true I would highly recommend clamping the coupler tightly to the tongue and drilling new holes.
I picked up a metal cutoff blade for my chop saw. Once I finish with a couple other projects I'll trim off the end of the coupler. I think I can cut the coupler at the left edge of the right-most bolt hole. However, now that I see the couple upside down, I hope that the welded in piece will clear the safety chains.
I installed the new coupler today. I had to relocate the safety chains from inside the tubing to outside. They new coupler would not fit in place with the chains coming out of the tubing.
The new coupler fits snug on top of the tubing and there is no movement. Where the coupler was cut, I primed and painted the bare metal.
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