upper bunk strengthening project
When I initially bought my Fuzion 302 in 2008, I saw that the upper bunk was pretty weak. Addressing the weight-bearing capacity of the top bunk was my first modification.
I cut 1" x 4" boards to the correct length to fit side to side inside the existing bed rails. I used 1 1/2" screws to attach the new side rail to the existing rail. Then using "L" brackets, I mounted 3 additional slats to strengthen the bottom of the bed. I added some foam padding to kind of fill in between the original and the new slats.
That bunk held the weight of two 18 year old girls, maybe 350 # total, pretty good before I fixed it, but afterwards, I felt much better about the loading and it didn't sag any longer.
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