Demco Flat-Tow Setup Instructions, with comparison to Blue Ox and Roadmaster

[realshelby]

My 2015 Wrangler (Sahara JKU) weighs about 4200 lbs, so when I tow it, I need to reduce the weight in my Transit 350-HD LTV motorhome. With its big wheels, it does roll well, but the Maverick is much more efficient as a towed for me.

My 2017 Wrangler Unlimited Rubicon Recon was 5140 lbs! With the big tires it pulled fairly hard. Had to remove spare, high lift jack, and watch how much fuel was in it to get under 5000 lbs,
Maverick tows much easier. Not sure if I am getting any better mpg yet though.

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[BradnChristine]

My 2017 Wrangler Unlimited Rubicon Recon was 5140 lbs! With the big tires it pulled fairly hard. Had to remove spare, high lift jack, and watch how much fuel was in it to get under 5000 lbs,
Maverick tows much easier. Not sure if I am getting any better mpg yet though.

Yeah...that Rubicon is a lot beefier than our "Mall-crawler".

It is a Sahara JKU with the "X" package. Sorta rare with the fancy hood and decals. Only made in 2015. Tires aren't terribly big, and they are street tires (I bought it with them in 2019. The little 2-door in the back was my son's.

 

[SaltyJim]

There are quite a few threads in MTC about flat towing that I've been involved with, and I have gotten quite a few PMs about the install from members here as well as a Facebook group. So I made a file.

I had quickly put together a file in late January, but when I reviewed it, I realized that I had left a bit out. So I went back and tried to fill in the blanks today and remove typos.

Even if you do not want to attempt the relatively easy install, there may be some pointers you can see and share with your installer. It is a fairly easy install for the baseplate; wiring is always a pain.

My experience is that if you are in a hurry, buying directly from Demco was the fastest; and usually Tweetys is the least expensive.

Hope this helps someone here.

Thanks again, Brad! My Demco baseplate is getting installed by my RV dealer who has installed many baseplates, tomorrow. This will be their first Demco install, so I shared your fabulous write up about the install with them. I agree with others here who think Demco owes you a great deal due to your R&D work on their behalf. One thing to think about for those who may be able to afford it. I’m leery of tapping into the wiring (as is my dealer) due to potential warranty issues. So I’m getting a wireless tow light that can be attached to the Maverick with removable brackets or with magnets on the roof. I put on some paint protection film on the rear part of the roof for when I might mount it there. Is it pricey? For sure. But an option.

Thanks again, Brad!

 

[BradnChristine]

Thanks again, Brad! My Demco baseplate is getting installed by my RV dealer who has installed many baseplates, tomorrow. This will be their first Demco install, so I shared your fabulous write up about the install with them. I agree with others here who think Demco owes you a great deal due to your R&D work on their behalf. One thing to think about for those who may be able to afford it. I’m leery of tapping into the wiring (as is my dealer) due to potential warranty issues. So I’m getting a wireless tow light that can be attached to the Maverick with removable brackets or with magnets on the roof. I put on some paint protection film on the rear part of the roof for when I might mount it there. Is it pricey? For sure. But an option.

Thanks again, Brad!

You are very welcome.

My first towed was a 1998 Honda CR-V and I used magnetic lights for the same fear about getting into the wiring. Then on my 2003 S-10, the taillight assemblies were large enough for me to add another dual-element bulb to them by cutting out a new socket hole, so I did...but I still bought a second set of taillights from Ebay "just in case." Never used though.

From then on, I started using diodes. Before I bought the ones I listed in the file, I talked with the ebay seller a few times to be sure of his product. I've had an amateir radio license for right at 60 years, and I know that diodes are really simple components.

The current can only go one way through them, and each unit has 2 diodes inside, each sending power only to the output wire. So if you have power coming from the RV through the new wires you install to the diode, that power can only come out the output wire.

When you are driving the truck, the power from the truck also only comes out the output wire. The two input wires have no electrical connection to each other. They are safe, and Roadmaster has been selling its overpriced diodes with heat sinks for several decades now. I used to use those before, but cutting and putting terminals onto the wires, just to plug into the Roadmaster diode, was a lot of work. $51.30 vs $18.50 for 4 is also a consideration.

You have to do what is comfortable, and I certainly understand hesitancy to cut into the Maverick wiring. It is pretty easy to test a diode to make sure it is working properly by applying 12 volts to each of the input wires and then checking the output wire for the 12 volts...but no power will be found on the other input wire.

I am now far less worried about diodes, than the active shutter destruction from Roadmaster.

 

[Backdoctor]

Brad, I am wondering why the change line from the RV to the positive electrical “post” in the engine bay doesn’t work for you? Does the charge line not supply the necessary amount of power for the Mav while you’re towing? I use the brake buddy (select 3) and haven’t had the deep sleep issue I think you’re speaking of.

I also wanted to thank you again for the help figuring out the fit of the Demco base plate and my 2023 Mav. I had exactly the same issue you had ( the holes were slightly to close to the centre of the truck and wouldn’t allow the bolts to enter the slot intended). The engineers at Demco felt it would be ok to simply enlarge the holes by 1/8” in the outer direction to allow for the variance. I used a burr bit on my drill, and although it was a bit slow, it all worked out fine. I did add larger washers just for a little extra security.

 

[BradnChristine]

Brad, I am wondering why the change line from the RV to the positive electrical “post” in the engine bay doesn’t work for you? Does the charge line not supply the necessary amount of power for the Mav while you’re towing? I use the brake buddy (select 3) and haven’t had the deep sleep issue I think you’re speaking of.

I also wanted to thank you again for the help figuring out the fit of the Demco base plate and my 2023 Mav. I had exactly the same issue you had ( the holes were slightly to close to the centre of the truck and wouldn’t allow the bolts to enter the slot intended). The engineers at Demco felt it would be ok to simply enlarge the holes by 1/8” in the outer direction to allow for the variance. I used a burr bit on my drill, and although it was a bit slow, it all worked out fine. I did add larger washers just for a little extra security.

First, the charge line would likely serve the BrakeBuddy just fine (Hopkins allows 5 amps charging), but the issue is where to plug the BrakeBuddy in. The 12 volt outlet on the dash does not stay on. So my choice was to run another 12 volt socket out to the jump posts, so I'd have an always-live socket...or just try the little lithium power banks.

I actually have one rated at 206wh, one rated at 100wh, and a third one coming that is rated at 147wh. All of these recharge either by plugging into the Maverick while driving or by small solar panels...25w-50w. It is just something to try before I add wiring to the Maverick.

I had mistakenly thought in the past that the BrakeBuddy would engage without being connected to 12 volts (since the compressor was up to pressure). It will not...so I realized that I have actually driven a lot with the BrakeBuddy in place but not actually functional. My old S-10 had a dedicated, always hot 12 v socket to use, as does my Jeep. Maverick, not so much. One could also connect to the battery under the back seat, so long as you get on the right side of the BMS.

I just want to try the power bank style on the next trip as I think it is a simpler and more elegant solution. It works when bench testing/discharging/recharging the BrakeBuddy, and it looks like I could get many braking efforts out of the power bank. Triggering it 3 times left me with 94% power left with the 206wh unit.

Second. It sounds like you had the REVERSE problem. My first Demco baseplate had the holes too wide. Probably would have been perfect for you. When I talked with Demco last year, Kevin told me the engineer initially wanted to make slotted holes, but decided it wasn't necessary. His first instinct as correct. Overall distance for the outer holes looks to vary from 48-3/8" (mine) to 49" (likely yours). Maybe I'll remove the fascia from my wife's 2024 and see if the extra baseplate will fit there.
Or see if I can find a burr bit.

 

[Backdoctor]

Brad, I may be mistaken in that I believe the spacing on mine was the same.as yours. So I expect that I used the Burr to bring the opening closer to the centre. This is a few months and many miles ago. We've towed out to Colorado to ski, back to alabama to visit friends and currently we're in Venice Florida enjoying some well deserved sunshine. We'll head home.to Ottawa Ontario at the end of next week.

 

[BradnChristine]

Wiring issue:
I received a PM from a person telling me that his 2024 Maverick wiring was different for the rear lights. His message wasn't clear, and he is on the road towing so wasn't able to clarify yet.

He reported finding a solid white wire for the passenger side running lights...instead of what I listed for my 2023 Lariat Hybrid, white with a small orange stripe.

So please take care that you may have different wiring (I'm hoping that the orange stripe was just too small to see).

 

[B0B]

There are quite a few threads in MTC about flat towing that I've been involved with, and I have gotten quite a few PMs about the install from members here as well as a Facebook group. So I made a file.

I had quickly put together a file in late January, but when I reviewed it, I realized that I had left a bit out. So I went back and tried to fill in the blanks today and remove typos.

Even if you do not want to attempt the relatively easy install, there may be some pointers you can see and share with your installer. It is a fairly easy install for the baseplate; wiring is always a pain.

My experience is that if you are in a hurry, buying directly from Demco was the fastest; and usually Tweetys is the least expensive.

Hope this helps someone here.

Just wanted to thank you for these instructions!

Also, I shared them with the installer who installed my Demco Baseplate. He went through your instructions and I'm happy to say that no modification with the active shutter system was required! I specifically told him to keep an eye out for the 3rd and 4th vanes per your instructions but he said when he installed it, there was enough clearance that he didn't have to remove anything!

Maybe Demco improved the design? Either way, I did my first tow today with the Demco Commander 2 tow bar and the Stay and Play duo brake system. Everything was super easy to connect/disconnect. Your write up helped me narrow down to Demco over Roadmaster and Blue Ox. Thanks again!

 

[BradnChristine]

Just wanted to thank you for these instructions!

Also, I shared them with the installer who installed my Demco Baseplate. He went through your instructions and I'm happy to say that no modification with the active shutter system was required! I specifically told him to keep an eye out for the 3rd and 4th vanes per your instructions but he said when he installed it, there was enough clearance that he didn't have to remove anything!

Maybe Demco improved the design? Either way, I did my first tow today with the Demco Commander 2 tow bar and the Stay and Play duo brake system. Everything was super easy to connect/disconnect. Your right up helped me narrow down to Demco over Roadmaster and Blue Ox. Thanks again!

Congratulations! Glad it was helpful and you didn't have to pull the vanes. Probably variances in the Ford manufacturing. I haven't checked my 2024 to see if the clearance is different.

 

[rmhopper]

There are quite a few threads in MTC about flat towing that I've been involved with, and I have gotten quite a few PMs about the install from members here as well as a Facebook group. So I made a file.

I had quickly put together a file in late January, but when I reviewed it, I realized that I had left a bit out. So I went back and tried to fill in the blanks today and remove typos.

Even if you do not want to attempt the relatively easy install, there may be some pointers you can see and share with your installer. It is a fairly easy install for the baseplate; wiring is always a pain.

My experience is that if you are in a hurry, buying directly from Demco was the fastest; and usually Tweetys is the least expensive.

Hope this helps someone here.

Another thank you for your fine write-up about the Demco baseplate install. Finally got mine on, and your instructions were invaluable. 2024 Lariat, and I cancelled my Roadmaster order after reading your post and got the Demco. There as a manufacturing change in February (well, they added a few washers in the top brace in an attempt to avoid the cooling vanes), but I still didn't like the clearance and removed the vanes behind the baseplate bar. Do wish the Demco folks would learn from the Roadmaster engineers about providing proper mounting points for the wiring--I don't like what I had to do to mount those in a good place.

 

[BradnChristine]

Another thank you for your fine write-up about the Demco baseplate install. Finally got mine on, and your instructions were invaluable. 2024 Lariat, and I cancelled my Roadmaster order after reading your post and got the Demco. There as a manufacturing change in February (well, they added a few washers in the top brace in an attempt to avoid the cooling vanes), but I still didn't like the clearance and removed the vanes behind the baseplate bar. Do wish the Demco folks would learn from the Roadmaster engineers about providing proper mounting points for the wiring--I don't like what I had to do to mount those in a good place.

Looks great! Congratulations, and I'm glad you found the write-up helpful.

Completely agree on the wiring location. They could do so much better. All my prior Roadmaster baseplates were easy electric installs on other vehicles.

I noticed on Demco's test vehicle picture, they completely left off ANY electric connection.

When I emailed them to ask about mounting, and got told "we leave that up to the installer", I figured it was sort of purposeful. They were so late to the production, I think they just wanted to get the baseplate out.

 

[phoneman01]

I finally got the chance to start on my Demco install yesterday. I removed the fascia and installed the plate successfully(with lots of help from your extra instructions). I found a way to mount the breakaway and ran the leads for same along with a fused 12v power supply for the Brake Buddy. I ran a fused charge wire lead with diode to the positive jump post.
Now for the caveats, I can't seem to figure out where to mount the 6 pin round and did you use a lift to run your taillight/brake wiring? My floor jack and stands don't seem to get the truck high enough for me to remove the undercovers.

 

[BradnChristine]

I finally got the chance to start on my Demco install yesterday. I removed the fascia and installed the plate successfully(with lots of help from your extra instructions). I found a way to mount the breakaway and ran the leads for same along with a fused 12v power supply for the Brake Buddy. I ran a fused charge wire lead with diode to the positive jump post.
Now for the caveats, I can't seem to figure out where to mount the 6 pin round and did you use a lift to run your taillight/brake wiring? My floor jack and stands don't seem to get the truck high enough for me to remove the undercovers.

I did it all on the floor in the garage, not lifted at all. I did take the edges of the undercovers off, but not the whole thing. I then put the wires into place and reattached the few connectors that I had removed. I worked from the rear to the front with the wires.

I discarded the way-too-large and heavy Demco 6-pin plate and bought a much smaller metal plate from Amazon for about $6. I mounted it "lip forward" into the slot made by the horizintal part of the grill. I used 3M VHB tape to secure it there, just atop the baseplate bar. Same thing (3M) for the smallest Hopkins breakaway switch I could find for the BrakeBuddy which is mounted on the safety chain flat area.

Here's the closeup of the electric. Demco screwed the pooch on preparing for a 6-pin mount. They could have done much more than just toss a big mounting plate in the box. Notice the 6-pin is upside down and I used a grinder to remove a lot of the tab. 6-pin is plastic. I also cut the rear rubber sheathing on the inside, made sure the wires all were bent and coming out of the side...as straight out the back looked too close to fins.

 

[phoneman01]

Wow Brad! I mounted my after market breakaway on the bar with a self tapping screw. I can't fit well under the truck,even if I jack up one side. You must be skinnier than this fat boy. I WILL get the wire ran though. I may try something new on mounting the plug. Thanks for the quick response!

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