This morning I had an engineers intense look at the drop down tabs.
They were so badly made that one would have never ever have reached the full drop down limit . I also noticed that the little nibbles on the inner slot were not uniform . In fact two were missing on one save for a very minimal indentation & I'd never noticed it till this morning .
To solve the problem I used a 1/4 inch second cut half round file and filed out new gouge holes to a new line I'd scribed on the metal , giving each gouge out a decent almost half round shape and making a decent point at the next gouge .
The upper most gouge hole was redefined to a slightly bigger hole so that when it sits on the pin in the fasteners anchor it hangs lose and is fully dropped down .
Lastly after a couple of trial refits I decided that it would be OK to have some sort of compression rubber to oppose the closing of the tailgate as this would help ensure the catches stay locked when traveling .
For this I used two rubber grommets that an electrician fits in a metal double socket back box to protect the cables . With a bit of silicone grease & no little effort I managed to slip them over the body of the fastener and push them up flush to the metal they are anchored in .
Closing the tail board this time round worked well , giving it just that little bit of resistance needed to see the drop links secure.
As an extra precaution I used two ratchet strap to pull the tail board in taught so if the fasteners did come lose the tail board would stay in place .
I then took the trailer & car to my pals . he lives up a 3/4 mile long very bumpy stone track .. Both the drop links were still fastened tight in both devices .
Thinking itn through after reading the posts I've decided to get so 200 mm long light contraction springs and fashion hooks at each end of them for them to fit in the bottom of each drop down link & hook over a self tapping screw so there is tension in the springs as they pull the links down & keep them there .
I think this is a better idea than bungees as they don't decay with UV light like a bungee does nor should they flap around and stretch .
I did see a horse box tailer earlier tonight that had two sets of " Antiluce " type fasteners on each side of the tail board .. that seems a very good idea to implement the next time & have £ 25 or so spare..
Thanks
Dave