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If your battery checks fine and it runs on AC the problem would seem to be between the unit and the battery. Sounds like a bad connection, is there anyone close to you that can lend you a factory DC cord to test if your's is good? Some 12v cords have a fuse built into the plug its self?

Really pretty simple, solar panel to controller then to battery. Finding good connectors for the panel to controller is a key part as I'm assuming the panel is not permanetly mounted/ displayed but must be deployed manually? Depending on wire/cable type either Anderson Power Poles or SAE...

I stock the disposable single serving ones in my kit, light and sturdy.

Contact the guys at SPOD 4x4, I think they are well versed in this may even have a drop in replacement

Try searching your local antique shops for a old style metal milk crate. They work great especially if you can find the smaller size, it just fits a 20 lb cyl. I suppose you could even use a good plastic one if you checked it periodically for cracks or sun damage

Operator error?

I'm confused, if some part stripped out one would think the top would just continue to the fully open or closed position. Sounds like the handle slipped out of your hand and free wheeled around and whooped you. Don't ask me how I am familiar with this action. :eek:

Google 80-20

use 3/8 x 4" aluminum flat bar stock bolted first to bed? remove plastic rail caps first

I'd be very careful with the starter fluid, in years past it caused the glow plug ends to mushroom thus preventing easy removal/replacement

Military old style duffel bag? Tough hoseable and has strap for carrying

You must have been watching me :victory:

Seems like you have nailed it!! You won't regret this install

Probably waiting for an east bound on ride on I-40 in downtown Barstow?

Realizing I may be late to the party but use of PB Blaster or similar (negating the need for disassembly) certainly wouldn't hurt

:lurk::lurk:

Great, glad all turned out well

You know how hard it is to resist not taking the obvious pot shot at this post?

Does your 2 gallon units have the date stamps on the bottom? That would perhaps help solve the mystery

No date stamps sounds like you may have gotten some fakes? In any event you have gotten a sterling example of how a standup company handles issues