Super Easy Flat Tow Setup w/ Roadmaster Nighthawk, Demco Stay-in-Play Duo SBS

[Dad]

Waited a long time for this kind of information. This is a game-changer for us who wish to flat tow our Mavs and are dissatisfied with the crappy designs put forth by both Roadmaster & Blue Ox.

Just so I'm clear . . . you used a Demco baseplate with a Roadmaster tow bar?

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[BradnChristine]

Waited a long time for this kind of information. This is a game-changer for us who wish to flat tow our Mavs and are dissatisfied with the crappy designs put forth by both Roadmaster & Blue Ox.

Just so I'm clear . . . you used a Demco baseplate with a Roadmaster tow bar?

I am planning on it. My baseplate remains on the garage floor as I have a quick trip to take towing the C-Max and no time to get it set up on the Maverick.

Demco sells an adaptor to Roadmaster towbars; and Roadmaster sells an adaptor to Demco Baseplates.

When I checked, the Roadmaster adaptor seemed to be half the price of the Demco adaptor. I have both a Roadmaster Stowmaster towbar and a Roadmaster Falcon 2 towbar. I *think* the below is the right one, but I have not fully investigated. yet and I'm not positive. I've never used anything DEMCO before.

 

[DavidLs]

I havee been looking for a way to put a brush guard/Push bar on a XL Mav. . I wonder where in install data is. Pic i mean

 

[BradnChristine]

I am planning on it. My baseplate remains on the garage floor as I have a quick trip to take towing the C-Max and no time to get it set up on the Maverick.

Demco sells an adaptor to Roadmaster towbars; and Roadmaster sells an adaptor to Demco Baseplates.

When I checked, the Roadmaster adaptor seemed to be half the price of the Demco adaptor. I have both a Roadmaster Stowmaster towbar and a Roadmaster Falcon 2 towbar. I *think* the below is the right one, but I have not fully investigated. yet and I'm not positive. I've never used anything DEMCO before.

I ordered a pair of these today from Amazon for $48.92 shipped. I will report if they fit or not, but they look like I just need to remove the old bolt on the end of the Roadmaster Falcon 2 and pull off the end piece and replace it with these and the new bolts.

 

[Dad]

I am planning on it. My baseplate remains on the garage floor as I have a quick trip to take towing the C-Max and no time to get it set up on the Maverick.

Demco sells an adaptor to Roadmaster towbars; and Roadmaster sells an adaptor to Demco Baseplates.

When I checked, the Roadmaster adaptor seemed to be half the price of the Demco adaptor. I have both a Roadmaster Stowmaster towbar and a Roadmaster Falcon 2 towbar. I *think* the below is the right one, but I have not fully investigated. yet and I'm not positive. I've never used anything DEMCO before.

Thank you!

 

[BradnChristine]

More news about DEMCO:
I started the install this morning and after I got the fascia off, I started to mount the towbar baseplate.

IT DID NOT FIT.

I measured the lower, outer two bolt holes and the baseplate has them spaced at exactly 49" center to center. My 2023 Maverick's outer two boltholes are spaced exactly 48-3/8". Here are pictures showing what happens when I bolted up the passenger side with my helper holding up the baseplate.

I contacted a friend who also has a Demco baseplate and his baseplate also measures 49". His fascia has not been removed yet, but it is likely that his Maverick is the same 48-3/8" distance.

My suspicion is that the truck Demco used as a model may have had some differences in manufacturing. I have sent them a message and asking what to do now.

I'm no engineer, but I think they may need to use elongated holes...elongated 5/16" toward the center...or just take 5/16" out of the center of the bar if their model was faulty. The 4 holes in the Maverick are on a single length of square tubing, so there really should not be a manufacturing difference at Ford.

 

[realshelby]

The way that looks you would have to take some out of BOTH sides to keep the holes from being too close to the edge of the plate. Fixable, but I wonder how they are that far off?
BTW, how does the top of that plate mount? I am trying to figure out how Demco is attaching to the main "frame" up there?
Will those other holes work with the bottom ones so far off?

 

[BradnChristine]

Demco is responding admirably. Apparently the initial Maverick model had the holes wider spaced. They have sold 5 units so far, but reported that they have now pulled the remaining stock off of the shelves. In my initial contact with them, the engineer reportedly thought about slotting the holes, but they thought Ford was consistent enough that they could count on just drilling a hole that would fit all. Nope. I've sent them my measurements and several pictures. I have faith that they will handle it. I knew when I took off the fascia that the truck could be "out of commission" for a while, and that isn't a problem for me. I just wanted to alert others not to take their fascia off and start the install if they purchased one.

There is an s-bar that attaches to the top of the main baseplate to add structural stability. It is bolted on. I didn't get that far.

In actuality, it looks like all 4 holes should be slotted to the center 5/16" and that would solve the issue for any variances. The baseplate holes are 49" center to center, while the truck is 48-3/8" center to center with the bolts installed. Ford did not center the bolts in the holes, so you must leave the bolts in to accurately measure.

By the way, it completely goes in front of the active shutter system. There is a rubber/plastic active-shutter shroud that will need a little trimming on the sides. I chose to take my shroud off to test fit and then cut as appropriate (2 push pins and release 8 clips). But I got stopped at that point.

Incidentally, I verified that none of the other retailers have even ordered the baseplate, so I find it interesting that one promises a really low price and one promises an October retail delivery of what they don't have. I'm glad I went direct with Demco. I'll report the resolution as soon as I get it.

 

[jmcarter]

Thanks for the update….anxious to get mine ordered. I’d even consider driving to their plant in Iowa so they could use my 23 Hybrid for fitment.

 

[BradnChristine]

Thanks for the update….anxious to get mine ordered. I’d even consider driving to their plant in Iowa so they could use my 23 Hybrid for fitment.

They are still working on the solution this week, and will most likely slot the lower 4 holes in the baseplate to accommodate Ford's inconsistencies. Here's what I know so far:
1. The model they used for the baseplate apparently had an overall bolt-hole spacing of 49".
2. My 2023 has a spacing of 48-3/8".
3. A friend's 2023 has a spacing of 48-1/2 (possibly 48-5/8).

First year buyer issues.... But at least they are getting it resolved.

I don't know if they do any installs now at the factory, but the shipping costs for this 50lb+ item may make a road trip worth it! Fascia removal was tedious but not hard at all, even with the truck just sitting on the ground. I fully turned the steering to the right (from seated in the driver's seat) to get all the stuff off. On each side where the fascia meets the fender, there is a clip in the center between the 3 - 10mm bolts that was a pain to get to release...the eTrailer video explains it.

One tip so far is to remove the 2 push-pins that are near the upper 2 release clips on top. The fascia will pull past them, as the holes in the fascia are shaped like "C" and open on the side around the pins, but then when they release, it will catch you off guard and I darned-near fell backwards with the fascia in hand. Pull the 2 pins out and then you can just give it a gentle tug to come off. The Roadmaster video I followed did not tell me to pull those pins.

 

[Dad]

Thank you very much for going down this rabbit hole! Seems what started out as a few hours project has got you involved in Ford's manufacturing anomalies and getting DEMCO to redesign their product. Many of us will benefit from your involvement.

 

[BradnChristine]

Thank you very much for going down this rabbit hole! Seems what started out as a few hours project has got you involved in Ford's manufacturing anomalies and getting DEMCO to redesign their product. Many of us will benefit from your involvement.

You are very welcome. It is a great baseplate, is simple to install (with the correct bolt pattern), it looks good and leaves the shutters alone. The issue we seem to be finding with the holes is that there is a lot of Ford variance. My Demco customer service guy tells me they had a similar problem with one of the Jeep baseplates and slotting was required to account for Jeep's manufacturing variances.

Demco is coming at this from a couple of directions: They have manufactured a new baseplate for me (and my narrowest bolt pattern) and shipped it yesterday. My friend has a Maverick with a wider bolt pattern, so they are having him just enlarge the 4 holes to 1/2"to see if that works. Both of our Mavericks are narrower than their initial model. I imagine Demco will end up just using about a 3/4" by 5/16" slot to accommodate all 3 bolt variations. I hope more variations don't appear!

At this time, I would advise anyone in a hurry to just take the fascia off and measure the outer 2 bolts, center to center before contacting Demco to order. That would give them more info as to exactly what the common measurement is: 49", 48-5/8" or 48-3/8".

I used the time to run wire for the taillights and the breakaway switch. I located diodes for the lights on ebay where you don't have to pay the Roadmaster prices ($45 for 4), nor do you have to crimp the connectors on as these have their own wires for $18.50 for 4. They should arrive today: https://www.ebay.com/itm/385511304724

If you have Roadmaster towbar, several of them can be adapted to the Demco baseplate by buying RM-034: https://www.amazon.com/Roadmaster-34-Adapter-Bar/dp/B003VAVZQ4/ My adaptors also arrive today.

 

[catu-ualos]

Waited a long time for this kind of information. This is a game-changer for us who wish to flat tow our Mavs and are dissatisfied with the crappy designs put forth by both Roadmaster & Blue Ox.

Just so I'm clear . . . you used a Demco baseplate with a Roadmaster tow bar?

 

[catu-ualos]

Everything above is what I installed, and it works great.

 

[BradnChristine]

Everything above is what I installed, and it works great.

Just hope for no heat issues that Ford argues with you about coverage since the lower active-shutter system had to be destroyed on your truck in order to use the Roadmaster baseplate. That is why I waited for Demco, but was almost resigned to do the Blue Ox install. Roadmaster = potential warranty issues; Blue Ox = hard to make into a pretty install. Demco solves both issues.

I know several have installed (or had installed) the Roadmaster baseplate, and I hope all stays well for them. I was cautious when I saw the Roadmaster instructions, because early on, someone in the group was told by their dealer that the Roadmaster baseplate could cause a warranty issue for them.

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