Ramp Door Construction

[HyperCamp]

Does anyone know how the TH ramp doors are made? I'm guessing it's mainly a 3/4 inch plywood decking sandwiched between the inner and outer finish. I'm just curious if anyone knows. THANKS!

[HyperCamp]

So, nobody knows? A real mystery.

[WolfWhistle]

Hyperlite and others have a Lippert door. It has an extruded aluminum frame... looks like 2 types... with 1_1/4" Styrofoam core and with 3/16" plywood on either side... The outside is 1/16" fiberglass (I assume Philon) ... all this bonded/glued together then a rubber mat glued down on the inside. The foam is in two parts glued/joined at the center.
WW

[HyperCamp]

Thank you so much! One more thing, is the seam in the middle, across the door from side to side, or up the middle from ground to trailer?
Thanks again.

[REPO]

You could probably email Forest River directly to see if your trailer has the lippert door, then just contact lippert for a drawing of the actual door.

[HyperCamp]

Thanks for the advice! I just talked with FR, and they assure me there is no "better" part of the door to use for loading. No weak points, etc., it's all the same for strength.
I appreciate the ease of talking to FR, nice folks!

[WolfWhistle]

The seam is vertical in the middle. That is where a single bike rolls up and where the first sign of failure probably will be. If. Not there, the bottom of the ramp will fail where the spring loaded hinges attach. The only drawing I have ever seen was by a forum member who Xrayed his ramp.I stitched mine together with 1/4" aluminum (inside) and thick aluminum angle outside (home-made tag bracket. It seems to help but more plates might be needed future
WW

[MTGunner]

My 27SBU Palamino has a damaged ramp door that is in need a solution. The wood near the hinges is damaged and the ramp door is buckling. I am concerned that the bolts will pull through the plywood. Has anyone had this issue and how was theirs repaired? MTG

[WolfWhistle]

Originally Posted by MTGunner

My 27SBU Palamino has a damaged ramp door that is in need a solution. The wood near the hinges is damaged and the ramp door is buckling. I am concerned that the bolts will pull through the plywood. Has anyone had this issue and how was theirs repaired? MTG

I don't know anything about Palamino ramp door. Maybe a photo or three showing the damage and buckling. These XLRs only have thin plywood each side, styrofoam, a little glue and 4 pieces of aluminum at only the edges.... 4 sticks of aluminum... oh and a prayer... holding them together.

[HyperCamp]

I would assume you should not ride a bike right up the middle, but rather pick a side.

[MTGunner]

I posted earlier that my Palamino has ramp door damage. After much labor I have found the ramp doors are very poorly constructed. But...I have removed the ramp door, removed exterior aluminum frame to find water damage and failed aluminum square stock welds. Having the aluminum tubing repaired, TIG welded, and will replace rotted 1/8" plywood with sheet aluminum and 1/8" aluminum diamond plate. MTG

[WolfWhistle]

Originally Posted by MTGunner

I posted earlier that my Palamino has ramp door damage. After much labor I have found the ramp doors are very poorly constructed. But...I have removed the ramp door, removed exterior aluminum frame to find water damage and failed aluminum square stock welds. Having the aluminum tubing repaired, TIG welded, and will replace rotted 1/8" plywood with sheet aluminum and 1/8" aluminum diamond plate. MTG

That's what XLR doors should be built like... welded and with big sheet of diamond plate instead of 1/4" plywood, styrofoam and glue.
Post pics if you can MTG

[andy29847]

I'm no longer an XLR owner and the ramp door is a big reason for that. My toyhauler had the ramp door replaced 2 times. Lippert/forest river paid, but my camper was still in the shop for 6 weeks each time. The door design is poor. I have seen brand new doors on the RV lot that are flexing. I reinforced the hinges on my new door and removed 3 (of 6 springs). I would recommend those actions to anyone with a lippert door. I have some pictures I'll share:

flexing at the bottom:


Lippert tag/sn:


Spring pressure when open:


Corner and hinge reinforcement:


Aluminum plate to redistribute the spring forces (note 6 springs still used here):


Final configuration:


Door cross section drawing (note, bottom hinge bolts are through aluminum frame, not through door material):

[340xlr]

Anyone seen me of the new moryde doors? Just curios on the operation and construction of the new doors.