Well after years of using the fenders as the step into the boat. And fighting the flimsy fender mounts cracking from vibration. I decided to build a nice strong step / fender mount.
I started with two cardboard templates and decided to go with the larger design. I still prefer the sleeker look of the triangle shaped step though.
I started with .25" thick 5" flat bar and welded it into the side of the I-beam, the fender mount portion has a slight angle to try to match the fender.
I also added a piece of aluminum conduit for the guide poles.
Then I welded diamond plate to the top of it all trying to weld from the bottom so as to not show off my ugly welds.
I have thought of trying to do something on the side plates to be more decorative. Like a light up Malibu emblem or something like that.
I don't have completed pics, but this is some of the damage done from how flexible the I-beams are currently.
I have had to repair two of the other cross braces before. I welded the crack from both sides, welded the cross support to the frame, and then added gussets under the boat that are welded to the top/side of the cross tube and into the bottom and web of the I-beam. I will be adding quite a few more gussets and supports to the I-beams to stop the flex.
Looking online it appears it is not uncommon to have flex crack failures on these I-beam trailers.