We purchased 2 pairs of Hullavators in 2008 and after considerable use over 8 years one of the gas springs failed.
I removed the gas springs and after discussion with Mr. Henk Blok at Gemini Gas Springs (Vernon, BC, 778-475-5611) sent him one of the GS that had not failed for identification. Mr Blok then sold me four “8/19 250-555/500N M8/M8”.
The cost in 2016 was approx. $25 per spring (including HST) and $27 in total for shipping .
These replacements are the same dimension as the originals and are rated at 500 Newtons (approx 110 pounds-force).
I tried various approaches for installing the new springs and eventually found that it can be accomplished fairly easily using some clothes hanger, 1/8" wire rope, wire rope clamps (the crimp-type do NOT hold) a 5" turn-buckle and some ‘S’ hooks plus odds and ends.
I shall post my approach with photos as time permits.
Comments:
To remove the old springs, with the Hullavator in the closed position, I first unscrewed the ROD end using a pair of needle-nose vice-grips. Caution: even old springs can be under considerable pressure so keep your fingers clear!
All the spring and fitting threads are right-handed on my Hullavators.
To install the new springs only one rivet needs to be drilled out: the one that carries the ROD end of the spring and that passes completely through the Hullavator. Removing more rivets makes the job more complicated not easier!
Because of the pressure in the barrel of the gas springs drilling or clamping them seems like a very bad idea.
Because these parts are under considerable constant stress, weakening one of the fittings that carry the springs by drilling a hole in it seems like a bad idea.
Are these spring heavier duty than originals. I have a 75 LB kayak. Thanks
Tim
Regarding gas spring strength:
The original Thule gas springs had no specifications on them and Thule would not provide this information so I sent Henk Blok at Gemini Gas Springs one of the original gas springs that had not failed and he determined it provided 500 Newtons or 110 pounds of force. Our kayaks, Delta 15.5s weigh about 52 lbs and the replacement springs work well although in hindsight I would go somewhat higher than 500 Newtons as it is easier to pull the Hullavator down than to lift Hullavator with kayak up.
Thule states that the load limit for the Hullavator is 75 lbs and that they provide 40 lbs of lift.
Gas springs are available in quite a variety of strengths.
Hi Tim,
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Be careful and be sure that everything is well secured - these springs exert a lot of force on a small area!
I’d be pleased to try and answer any questions that arise.
130 maybe?
130 lbs sounds reasonable but I have little experience with gas springs.
I suggest that you ask Henk Blok his opinion - he was very helpful when I contacted him.
Hi. Can you tell me if your 500N 110lbs springs fit well with your Hullavator rack ? Are the arms of the racks are too difficult too pull down to lock it without the kayak on ? And was it difficult to compress the springs and fit it ?
Do you recommand the 500N ones ?
Thanks
I do not currently need your instructions for the hullavator gas spring repair, but being proactive I have downloaded and printed them. You went through a chunk of work to create those instructions. It is greatly appreciated.
Yes, the replacement gas springs are a perfect fit but note that the 500N 110lb specification does NOT describe the physical dimensions.
With new gas springs the empty Hullavator arms are easy to pull down for loading.
When installing new gas springs the compressing using a turnbuckle as described requires little effort but holding them compressed while fastening them in place in the Hullavator was by far the most challenging part of the job.
The 500N replacement in use felt the same as the original.
De nada - it was an interesting challenge.
Thank you for your answer. It is aprreciated so much.
I will order the same at Gemini.
Have a good Day.
I just order the 580N/130 lbs springs for My hullavator. I went a little heavier since my sea kayak is 75lbs. Henk at Gemini was very helpful. He knows the exact dimensions and can custom make your desired poundage. He said the 500N/110lbs are about what the originals are. I’ll keep y’all posted on the outcome.
Tim
Hi. Which hullavator model you have ? 897 or 897xt or 898pro ? I have the 897xt. And the piece number is not the same than you indicated in an upper message.
Also do you think it is better to change the two springs or only the one broken if the old is still good ? Because I must know if I need to buy one or two springs.
For the price they ask me $33.50 each plus shipping and GST…
Thanks
Hello Kayako,
My Hullavators are 897XT.
Which piece number are you referring to?
My original gas springs had no useful identifying markings.
I would recommend replacing both gas springs at the same time.
The part number from Gemini is 8/19 250-599/500N 9.84-23.60/112lbs E 8.9/E8.9
I don t know why the part number is not the same.
The ones you had from Gemini were good as you said ?
The replacement gas springs have now been in use for 3 years and continue to work as well as the originals did.
My spouse and I paddle Delta 16 kayaks with a rated weight of 48 lbs.
Knowing what I know now (if only, eh?) I would go with a somewhat stronger spring, maybe 125 lbs. instead of 110 lbs.?
Using body weight it is easy to ‘cock’ the empty Hullavator in the down position for loading the kayak while bending and reaching under the kayak to release the locking mechanisms and assisting in the initial lifting is much more awkward.
Given that Thule supposedly has a lifetime warranty on the Hullavator for the original buyer, are they refusing to send replacements?
I as under the impression that Thule had pretty good customer service.
My understanding from Thule in 2018 is that they will replace defective parts (for the original owner) but that they will not provide any replacement parts that require disassembly of the Hullavator.
I’ve been following this post. With the information supplied here and other you tube videos online was able to change the springs in both sets of used Hullavators I bought with worn out springs. Henk at Gemini was very helpful and knew the exact size I needed. I decided to go with 120lbs force, about 535N. The old springs were super easy to remove by drilling a small hole to release pressure. They simply unscrew, no need to drill out the rivet.
I compressed the new spring with a floor jack between the floor and my work bench. Held it in place with hose clamps, sand paper and a piece of close hanger. It took a couple tries to get it right. You want it to short enough to give you a little room to work. Gotta make sure you put the clamps where they are accessable when removing.
When putting it back together I screwed the body side all the way in, then lined up the rod side, screwed it in 1/2 way backing out the other side 1/2 way. You can then release the pressure by cutting the wire or loosening the clamp on the body side. Then finish by screwing both sides in tight and removing all the clamps and wire. They work like new!
Thanks to all for the information and comments. I’m about to order the struts and with the help from a friend, replace all 4 on my 2 sets. My original Hullavators are 16+ years old. New ones (as of summer of 2023) are $950/set of two.