Sorry, I've been on vacation myself...so this is the first I am digging into this.
Here are some initial thoughts (take them for what they are...thoughts).
1. Steps. it appears as though the steps may have caused a chain reaction in problems. Steps, then fuses, etc. I wish we could incorporate the steps into the sidewall like we do our other lines, but its just not workable on Solera. Dealer should have been able to remedy this issue before it ever delivered.
2. Outdoor grill gets shipped in a box. Complete set. I know, because I have been at dealer shows...found the box and set the grill up for the dealer (Assembled the ENTIRE grill). I'm guessing this unit got set up at a show, they just pulled the grill out of the box, not all the pieces and then the box got thrown away. When you get the grill it is missing the regulator. That is why when I put it together...I put it all together instead of just trying to "show off" the main grill section. That way, nothing is lost or missing.
3. Cigarette burn. Could have been delivery driver, there is no smoking in our plant. If it was a weld burn...we normally leave plastic on the seats...so maybe it is something we missed.
4. Solera bed. I was at a dealership when they were taking it in and out, in and out at a show. They caught the bedspread in the track, it jumped and became "misaligned" in the track. One side was 2-3 teeth higher than the other. Instead of fixing it, they kept running it in and out causing further damage.
5. No reason for an inner dual to lose air sitting there. No idea on that. What did the repair guy say?
Don't get me wrong...I know that sometimes things are missed, but it's not always on Forest River QC. We can't catch a cigarette burn after it ships, the dealer has to catch that one.
We have a pretty extensive checklist that goes with the unit down the line. We have a final finish QC department and an "online" QC department. They are tracking issues beginning and middle of the line. No way do they catch 100%, but there are certainly checks and balances in place to try and catch it all. If I can find a copy I'l post the checklist. In the meantime I hope the dealer is doing everything they can to rectify the issues.
As for warranty, I have never seen our guys deny something that was clearly an existing issue (non-resolved issue) even if it was out of the warranty period. Just don't let it linger on too long.
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I am here by personal choice, not as the official voice of Forest River