Idea 1 will not make a difference. The upper cross bar supports are attached to the same cross members as the rollers.

The only options I see are taking the upper rear cross support off load trailer and reattach. The advantage of this is that you can step the mast while the boat is on the trailer.
or
Contact Trailex and see if you can purchase longer supports for the double stack.
or
Make your own extensions.

Zach, maybe you can find some aluminum channel that will slide into the upright supports. Attach the crossbars to the new channel and slide into top of uprights. Drill a hole through the uprights and new channel for a keeper pin. Two positions, one down all the way, and one up high enough to allow the H16 to go underneath. The new channel would not really carry any load, just be there to retain the top rack when you slide it up.

P.S. Check to see if that aluminum used for the cat trax rack will fit inside the uprights... That is a standard aluminum extrusion used in shop tool setup. It is available from McMaster Carr, or maybe a local industrial tool supplier.

http://www.mcmaster.com/#t-slotted-extrusions/=mzc0cq


Mike

Somebody had to say it.

I like this idea! I'll see what I can find. Thanks Mike!

I have two cats at the moment and its killing me not being able to easily use the bottom rack of the trailex.

Went out and tried the extrusions from the cat trax rack and they just barely don't fit inside the rear posts. Maybe they will fit if I sand them down...

I'm going to shop around for some standard square aluminum tubing around here and see what I can make fit.

Check with Trailex and explain what you are trying to do. They may have an extrusion that will work. I have worked with them on an trailex trailer I was rebuilding and they were very responsive to any requests or questions.

I emailed Carl at trailex asking if they have any extrusions that would fit and his email said this: "We do not".

I'm going to go around to some stores and shops around here tonight to see what I can come up with.

Looking at the shape would it be easier to find a piece that would fit over the outside?

I think I found a square aluminum tube that will work. I'll install it this weekend.

Here are some pictures:
I lifted the offending crossbar up just to see how much height I need. I need an inch or two more than this.

And then I moved the extrusion that connects the front and rear crossbars slightly off-center. This will keep it out of the way of the H16 mast cup.

looking at the pic where you have the bar held up...I'm thinking that the simple solution is to make four new splice plates (that triangle shaped piece) that are taller and double them up front and rear of each bar to give it even support (now that it's not sitting on the lower upright). That shouldn't be expensive. It might not be just a simple triangle anymore (to avoid too large of a triangle that gets in the way) ... but, easy peasy.

The angle is difficult to see but the upright is not the same width as the crossbar. So I can only put a plate on one side.

Just a couple of round spacers (tubing cut to length) and longer bolts will make up the difference.

Can you use the square piece that ties the front and back cross bars together to make new legs for the rear (if it is long enough). You can then replace the tie piece with just some square tubing, 2x4, or round pipe. It looks like the rear uprights should be square anyways. How much is it just to buy a new piece of stock from Trailex and be done?

Turns out I didn't get the second cat that I was expecting. Im tempted to sell this trailer and just use the regular trailer. I'm reluctant to sell it though because its such an awesome trailer. It's for sale locally here in Florida to see if there's any interest.

Is there a market for just the double stack components? I keep looking for a used trailex trailer but the only ones I see for sale are the double stack.

There was this guy who asked about upgrading his to a double stack. If he hasn't done it already, he may be in the market for the upper pieces.

http://www.hobiecat.com/forums/viewtopic.php?f=9&t=46064&hilit=trailex+double

How much is the double stack option new? I looked on the trailex website and could not find it.

I haven't seen any prices either.

$700 iIRC

I placed an ad on this site. Let me know if you're interested.