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Old 09-02-2014, 01:22 PM   #1
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Unhappy Build Quality

Just bought a XLR Hyper Lite 29HFS and after 4 weeks of use it continues to fall apart. Every trip a cabnet door will open and the 1/8 inch long hige screws pull out. I find "spare screws" everywhere and later find where they fell out of. Screws started to pull out on the tie downs and I got some grade 8 bolts. I wrapped several wires that would have rubed through and caused a short. Rust is already showing on the frame through the paint. Side door latches spun on the screws and I spent time getting them open and lock tighting them back in position. And the list goes on.

Any fixes for the cabnets? Better latches? I love the look of the vehicle but hate fixing things every 5 minutes. Is there someone at Forest River I can call and complain to? Nothing will happen but I would feel better.
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Old 09-02-2014, 01:29 PM   #2
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The root problem is overtightening the screws during installation, they strip the very very soft wood like cabinet substance the cabinets are made from. I found the following very successful:

unscrew the fixture, put one (and I mean one) drop of gorrila glue into the offending hole, wait 4-5 minutes, then screw it back in. use Duct tape to hold the cabinet door in place for about an hour and the screw how has something to hold into.
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Old 09-02-2014, 01:48 PM   #3
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We are beginning to hear that there are quality issues with the new units coming off the line. I think they just cannot build the units fast enough and the quality is being harmed.

Your not the first poster to mention this.
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Old 09-02-2014, 10:20 PM   #4
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I've written in several other posts, I'm the North American Quality Assurance Director for a major company and these quality issues need to be brought to the attention of the manufacturing Quality / Sales departments. Going through the dealer is not the best option as they don't build the trailers, and their job is to sell what is delivered. All the warranty issues everyone has are post-delivery problems which are "built-in" costs and so causes the manufacturer no financial pain.
Google Forest River, Elkhart, IN and you'll find a couple of phone #s. call them and ask to speak to the Quality Assurance Manager and register your dissatisfaction.
It's not until everyone who has quality issues gets involved in communicating, rather than just fixing it myself that things will change.
As I've said before: If we accept poor quality, then that's exactly what the manufacturer will deliver.
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Old 09-02-2014, 10:52 PM   #5
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Indeed, they need some QMS training certs and a few BSI audits to help get their act together...
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Old 09-02-2014, 10:55 PM   #6
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Quote:
Originally Posted by vinmaker View Post
We are beginning to hear that there are quality issues with the new units coming off the line. I think they just cannot build the units fast enough and the quality is being harmed.

Your not the first poster to mention this.
Beginning to hear? This has been blatantly going on since Hurricane Katrina IMO. When they started mass producing those FEMA trailers to ZERO standards is when I feel the industry took a quality nosedive that they have never pulled out of.
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Old 09-04-2014, 09:32 PM   #7
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No body cares

Quote:
Originally Posted by oxcamper View Post
I've written in several other posts, I'm the North American Quality Assurance Director for a major company and these quality issues need to be brought to the attention of the manufacturing Quality / Sales departments. Going through the dealer is not the best option as they don't build the trailers, and their job is to sell what is delivered. All the warranty issues everyone has are post-delivery problems which are "built-in" costs and so causes the manufacturer no financial pain.
Google Forest River, Elkhart, IN and you'll find a couple of phone #s. call them and ask to speak to the Quality Assurance Manager and register your dissatisfaction.
It's not until everyone who has quality issues gets involved in communicating, rather than just fixing it myself that things will change.
As I've said before: If we accept poor quality, then that's exactly what the manufacturer will deliver.
After my second round of problems I sent an e-mail to Bryan Stevens @BStevens@forestriverinc.com. He is the XLR GM, never heard a word. They have our money and don't care.
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Old 01-27-2015, 06:22 AM   #8
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Originally Posted by gmflanigan View Post
After my second round of problems I sent an e-mail to Bryan Stevens @BStevens@forestriverinc.com. He is the XLR GM, never heard a word. They have our money and don't care.

Does anyone know if this guy is still the GM for XLR? Is he considered the Plant Manager? Because we sent a long list of issues we have with the 2015 we just purchased. Quality Control and Craftsmanship is an issue; and relating back to the guy who had screws falling out; we have screws stripped where the Cargo Lights were installed in the fiberglass, and consequently while traveling in the rain had a MAJOR water leak, with major damage to the front wall, including the growth of black mold; which tells me that water has leaker here previously. We can't use the trailer because my husband is severely allergic. The Warranty Dept. is assisting us, and seems to be on top of it; we'll see because we just sent them all of our concerns yesterday. I was just wondering if this guy Bryan Stevens, is the Plant Manager for XLR? And if they will actually respond to our concerns. I know the water leak is a warranty issue......but the other issues we brought to their attention, well, we will see how they respond.

I agree with Oxcamper, if we don't bring these issues to their attention.....then its irresponsible on our part; and the Plant Manager doesn't know what the quality of their product "really" is after it leaves the Plant. Bottom line is we are the end user, and we have control over how we market their product to our peers. Seem to me a big name like Forest River would be concerned about that....maybe I'm wrong, but I hope not!!

We personally meet hundreds of people on the road, and in ATV parks because we trail ride.....we either give them a thumbs up, or we don't.

Just my two cents.......rant over !!
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Old 01-27-2015, 07:49 AM   #9
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Quote:
Originally Posted by oxcamper View Post
The root problem is overtightening the screws during installation, they strip the very very soft wood like cabinet substance the cabinets are made from. I found the following very successful:

unscrew the fixture, put one (and I mean one) drop of gorrila glue into the offending hole, wait 4-5 minutes, then screw it back in. use Duct tape to hold the cabinet door in place for about an hour and the screw how has something to hold into.
Alternately, you could break off a couple of tooth picks in the hole and put the screw back in.
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Old 01-27-2015, 02:34 PM   #10
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Or jam some steel wool in the hole the screw into that.
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