Don Payne, Happijac's New Product Manager
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Don and his daughter and Four Star camper
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Don's family camping in their Four Star camper
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When we ran our tour stories from Happijac, “Happijac Part 1: The History of Happijac” and “Happijac Part 2: Torrington Thrust Bearings and Beyond”, a few readers wrote in with questions they wished we had asked. Don Payne, Happijac’s new Product Manager, agreed to answer these questions and others that are often voiced in forums and in the marketplace about Happijac products. Don was actually quite enthusiastic about the idea and took the questions head on. Before we get to these questions, we start our interview getting to know Don.
TCM: Tell us about how you and your family got into truck camping.
Don: I grew up traveling back and forth from my home in southern Utah to southern Alberta with my family in my father’s truck camper. My father grew up in Alberta and we would visit his parents every summer. I had years of happy memories with my brother and sisters in that truck camper. Then my wife and I decided we would like to become RV owners. We had a nice Chevrolet ¾ ton long bed 4x4 and thought a truck camper would be great. We bought a “seasoned” Four Star 10 ½ foot unit and started enjoying the truck camping life.
TCM: What do you like to do when you go truck camping?
Don: We loved to go to Glacier National Park in Montana and spend a week fishing, hiking, and enjoying the wildlife. We would return to Glacier five times and many fond memories have been made. Our family is almost grown now and our four daughters look back on family vacations and “the camper” as some of the happiest times ever.
We have taken the truck camper to central California several times to visit relatives as well as southern Utah to visit my parents. We have gone up in the Uintah Mountains east of Salt Lake City with our canoe and done some nice fishing for the finest trout to be caught.
TCM: How did you come to work for Happijac?
Don: I have been in sales and sales management for twenty-two years. I have spent the last portion of the decade promoting the Little Giant Ladder up and down the west coast. Happijac brought me on board to further define and develop the truck camper tie-down and turnbuckle market along with the truck camper jack market. Happijac has been a leader in the truck camper tie-down/turnbuckle and jack market for years. I wanted to be part of a company that was such an innovative leader.
TCM: What is your job description at Happijac? What do you actually do?
Don: I have been given responsibility for the product lines of the jacks, tie-downs and turnbuckles. I am working with dealers, distributors and camper owners, helping them better understand Happijac’s fine products and their features and benefits. I hold training sessions regarding installation, use, and the reasons Happijac provides a level of comfort and safety that is needed in the industry. The Direct-to-Frame System utilizes the front of the truck bed and the truck frame to form an I-beam truss that provides excellent control for the largest and heaviest campers on the market by only adding twenty-seven pounds to the GVW.
TCM: What are your goals at Happijac for 2008?
Don: My goals are to inform and educate regarding Happijac tie-downs and turnbuckles and jacks so truck camper owners realize that a truck camper can become part of the truck and not just a shifting payload. I want the present and future owners of truck campers to know that driving ease and safety does not have to be compromised. A truck camper can be controlled and held fast with no bucking, twisting, or sliding. I also want to dispel the misinformation about Happijac that some seem to be promoting. I want the camper industry to better understand how safe our jacks are. If I am successful in these goals then my time will be well spent.
TCM: What makes Happijac products unique in the marketplace?
Don: Back in the 60’s, truck campers were a lot more popular and many people owned truck campers. The only tie-down systems then were belly bar type systems and bolt under the truck tie-down systems. When Happijac developed the bolt to the bed system it was adopted and embraced to such a large measure that Happijac market-share was very comfortable. This was because the Happijac tie-downs controlled truck camper movement in every direction. As truck camper owners were very familiar with the hazards of a camper that moves independent of the truck, they quickly realized how nice a truck was to drive when the camper was part of it and not just a moving, shifting payload.
Changes were made and the Direct-to-Frame Tie-Down System was developed. This unique system still utilizes the front of the truck bed but also ties to the frame and with the stabilizing bar forms a very strong structural I-beam truss. This design uses the same principles used in over-pass designs. An I-beam is very strong and supports weight from the top. A truss is designed to utilize principles of physics to minimize weight and maximize strength. This system is very capable and holds all truck campers solid and secure.
Often the simplicity of the rear Happijac bumper anchor is viewed as inefficient. It is very efficient and effective. Testing has shown that a truck rear quarter can be lifted off the ground with just the bumper anchor and nothing else. As of late, some bumpers need to be structurally strengthened and in those cases we supply a bumper brace to do the job.
The Happijac camper jack is the result of over thirty-five years of research and testing. These jacks are designed as camper jacks and not redesigned trailer tongue jacks, as others are. Happijac jacks are completely upgradeable. Every manual jack can be easily converted to electric with the addition of a motor kit. A jack is a mechanical device that wears with use. When it does it will not become unsafe. There is a “double nut” system to prevent injury. This is very important to camper owners. Happijac jacks will fail-safe and that means if something breaks it will hold the camper from coming down.
Many people may not know that Happijac is
also the leading supplier of camper slide-outs. Happijac developed the first slide-out mechanism for campers. Happijac continues to lead the industry in innovation and design while focusing on strength and safety.
TCM: Who is responsible for research and development at Happijac?
Don: There is a team that consists of Marty Rasmussen, Gary Scothern, and Chad Johnson. Marty heads the research and development team and has for over thirty-five years. He is the company founder. Innovation is the key to our success. Marty and Gary have been working together developing products and responding to the changing truck models for twenty-five years. Marty is an inventor at heart. He is a physicist and mathematician and is one of the best when it comes to visually perceiving a solution to a given situation. Gary and Chad are very proficient at converting ideas into practical prototypes. The team is very good at what they do.
TCM: Talk to us about Happijac build quality.
Don: Happijac is very focused on quality, reliability and safety. Happijac is now owned by Lippert Components and quality still remains very important. Happijac has invested in state-of-the-art CNC drills, mills, and lathes to produce high quality. This is technology that allows very close tolerances and extreme accuracy. We utilize a five-step powder coating process that provides a high impact resistant finish to our painted surface products.
TCM: How many Happijac tie-down and turnbuckle systems have been sold to date?
Don: We estimate over a million.
TCM: How many Happijac tie-down and turnbuckle systems were sold last year?
Don: We don’t generally discuss specific sales numbers but suffice it to say Happijac tie-downs and turnbuckles are used widely in the United States, Europe, Australia and Canada.
TCM: How many dealerships are currently selling and installing Happijac tie-down and turnbuckle systems?
Don: The majority of dealers. Our products are available at most all dealerships. Happijac continues to supply a majority of the tie-down market.
TCM: What is the warranty for the Happijac tie-down and turnbuckle system?
Don: These products carry a full one-year warranty from the date of purchase that covers manufacture defects. We have replaced turnbuckles that have older than one year but still show evidence of manufacturer defects.
TCM: What is the warranty for the different Happijac jacks?
Don: These products come with a full two-year warranty against manufactures defects. We have experienced success with all of our products performing as designed. We design safety into our jacks to insure the camper owner complete security.
TCM: How are warranty issues handled at Happijac?
Don: When a customer calls in with a warranty issue they are directed to speak with our customer service representative. Their issues are evaluated and dealt with according to the product and the issue. If a jack owner has a jack that is under warranty that needs factory work they are directed to send it in. We receive the jack and make the repairs and send it back out to the customer. This is the procedure because safety is such a concern to Happijac. If someone unqualified works on our jacks, safety may be compromised. If a tie-down or turnbuckle needs to be repaired the customer is asked to send it in or send in pictures and we will usually just replace it if there is a quality issue.
TCM: Talk to us about how to maintain Happijac tie-down and turnbuckle systems.
Don: The turnbuckles are made of stainless steel tubing with zinc plated screw hooks. We have chosen not to use stainless steel screws because of the galling that will occur when stainless steel is threaded to stainless steel. The spring in the front turnbuckle is plated chrome silicone and will never fatigue. The rear turnbuckle has a 1” polyurethane bushing/spring to provide the needed cushion without allowing the camper to gallop going down the road.
TCM: Talk to us about how to maintain Happijac jacks.
Don: The Happijac jacks are the strongest jacks on the market. They are engineered with redundant systems to ensure safe operation. They also have additional strapping welded to the bracket points so that the total thickness is 3/8”. This adds strength. Happijac has three different jack designs. The model 4150 is an acme screw system and uses a proprietary nut that greatly reduces friction. The higher the efficiency the lower the amperage draw on the battery. The other two jacks are ball screw systems that use 140 ball bearings in a two-circuit design. They are both 95% efficient. They are models 4500 and 4600. They are the same except for the drop leg feature on the model 4600. This allows the disengaging of the motor and with a push jack foot, the jack inner leg will go all the way to the ground without the aid of the motor. This speeds up the unloading process.
Maintenance of these jacks is often misunderstood. The main body of the jack is sealed and any maintenance or repair needs to be done by an authorized repair shop or Happijac. The screw of the 4150 is lubricated at the factory with synthetic. The 4500 and 4600 jacks are lubricated with a special rust inhibitor and lubrication. The crank socket does need occasional lubrication. There is a hole in the socket about a ½” in that is designed to receive several drops of 3-in-1 oil to loosen the short shaft mechanism that can tighten over time of un-use. Manually cranking back and forth will loosen the short shaft and free up a tight action.
Automotive wax should be applied to the black inner leg and the white outer leg of the jack just as if waxing the paint finish of your car, every six months to maintain the exterior of the jacks. This is outlined on our website, www.happijac.com.
TCM: Are there issues when dropping Happijac jacks on uneven ground?
Don: As with any truck camper jack, care should be taken when lowering jacks on any ground, especially uneven ground. Care should be taken to keep the camper level when loading and unloading. On uneven ground, the jacks must be operated individually after the first leg contacts the ground until each jack leg has contacted the ground.
When lifting a camper it is always extremely important to lift while camper is remaining level. If one corner of the truck camper is allowed to drop lower than level, there is a weight redistribution. It is a little known fact that one inch trop of a corner will add much additional weight to the jack on the low corner. The front should always be kept higher than the rear because this also distributes weight from the front, the heaviest half of the camper, to the rear, the lightest. Make sure to always have very solid jack footing. Gravel is a very big problem. Campers can become very unstable in a hurry.
Happijac has formulated The Golden Rules of Camper Handling. They are:
1. Always keep the front of the camper higher than the rear. Never allow the front of the camper to become lower than the back.
2. Always keep the camper level side-to-side. Stop frequently when loading and unloading to ensure camper is level side-to-side and the front is slightly higher than the rear.
3. Never leave the camper in an elevated position supported by jacks. Lower the camper to the ground or support weight on fixed platforms.
4. Always ensure that camper is clear of the truck bed when backing and pulling out.
5. Always remember that you are moving a dynamic load weighing thousands of pounds.
A dynamic load refers to weight shift. If a corner of the camper drops just a couple of inches, the weight redistribution is significant. It is like having a pan of water and you shift it off from level, the water/weight rushes to the low spot. This condition can potentially damage a camper and associated equipment. The vector forces dictate weight distribution.
TCM: The Happijac tie-down and turnbuckle systems require holes be drilled in the truck bed and bumper for installation. What is the advantage to this type of installation?
Don: The advantage is that the front tie-down anchors are higher and more inboard allowing for a much better angle for truck camper restraint. When you have an acute angle of pull forward and inward, the camper is held tight. This Direct-to-Frame Tie-Down System forms the I-Beam Truss we talked about earlier. When the anchor is very rigid and the in-bed components are in place, such as the centering guide locks, stabilizing bar and “L” bracket, then the camper cannot move forward, back, or side to side. When camper movement is controlled in this way, the driver experiences
a much more pleasant ride that feels under control. It is safer also. Another advantage is the reduction in weight. When you come from under the truck, you need much more steel to begin to hold the camper in the truck. But with the Happijac Direct-to-Frame System, we utilize the front of the bed as part of the structure to develop superior holding with less weight. Happijac adds twenty-seven pounds, not eighty to one-hundred pounds. The under frame systems also project out and offer shin and knee obstacles whereas the Happijac system is very minimal and out of the way.
TCM: Can you explain how the Happijac tie-down and turnbuckle system is frame mounted?
Don: The Happijac Direct-to-Frame System attaches to the frame through the floor of the bed through the cross-member, which is bolted to the frame creating the structural element. The Dodge and Chevrolet applications bolt to the frame and the Ford application bolts to the cross-member. This design is where the strength is achieved. The structural I-Beam truss is formed with the frame, the front of the bed, the stabilizing bar, and guide plates. Combined they form the strong Direct-to-Frame System.
TCM: Have you had any issues with the Happijac tie-down and turnbuckle systems damaging a truck?
Don: When the new body styles came out in 1999 and 2000, there were some issues where beds were damaged. These were a result of bed construction changes. Most of the problems were a result of flexing of the front of the bed and paint was rubbed near the anchor.
After researching these issues, it was discovered that in most cases the stabilizing bar was not installed or the system was not installed correctly. When the system is installed properly, we are not aware of any damage that has occurred. There was one case when we were still engineering the 2007 Chevrolet tie-down anchor. One of the initial prototypes did rub the bed and cause paint damage. We took care of the issue.
We have not had anyone contact us with a damaged truck where the installation was done properly. Instructions are included with every kit.
TCM: Some users say they experience noise when using Happijac jacks. Is this something you've experienced? Why does this happen?
Don: The Happijac jack is a very well engineered jack. It has a double brake system to insure safety. When the top brake plate is under a heavy load then the brake may squeak. It sounds like the jack is in need of lubrication when this noise is heard and some have taken it upon themselves to drill holes and pump in grease. This will not increase the efficiency of the brake but most likely will introduce dirt and metal filings from the drilling process that will definitely cause problem in the operation of the jack. Research and development is constantly working on improving and modifying the strongest jacks in the industry.
TCM: Are the Happijac jacks designed to handle the heavier truck campers that are approaching 6,000 pounds?
Don: The Happijac jacks are designed to operate safely with today’s campers. The Happijac jacks are the strongest made. The jack ratings are the rating ANSI (American National Standards Institute) designates for the acme screw and the ball screw. Some jack manufacturers rate their jacks much higher that the ANSI ratings. Happijac has chosen to use the ANSI rating and not some arbitrary number when rating our jacks.
This is a question that needs to be qualified. There is no jack on the market that can withstand the weight of a falling camper because of a shifting load. The dynamic nature of a camper can cause a very unsafe condition to occur if the weight of the camper is shifted excessively to one jack.
TCM: What are the advantages of the Quik-Load turnbuckles?
Don: They are lightweight yet very strong. They allow easy and fast adjustment because both hooks can be affixed and the barrel can still be adjusted after installation, locked and then clamped closed. The E clip issue has been resolved and confident safe camper tiedown is a result. They are stainless steel to eliminate corrosion, of course. The Quik-Load turnbuckles are a very good value.
TCM: Is there anything else you would like people to know about Happijac and Happijac's products for truck campers?
Don: Yes. Happijac is committed to quality and safety and strives to provide high quality products at a very good value.
Happijac’s Direct-to-Frame Tie-Down System is not only strong but provides excellent camper stability and combined with our highly engineered turnbuckles, camper movement is controlled in all directions without the need of a rubber bed mat which only reduces movement. Our tie-downs only add twenty-seven pounds. With the Centering Guide Locks in place, side-to-side movement is controlled. The pair of Front Guide Plates offers 180 square inches of protection to the front of the bed. We offer value.
There is a lot of misinformation out there regarding Happijac and our products. Happijac products are safe, easy to use and very effective. Contact us if you have any questions. We invite the opportunity to inform with facts. Happijac will make you a believer.
For more information about Happijac, visit their website www.happijac.com.
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