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Old 11-26-2015, 11:22 AM   #11
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The engineers at Lippert are looking at my pics. When I look, I see 3 things. Poor door construction, hinges too short, springs too strong.
I don't want to be critical of them (Lippert) but I will be. Hopefully they fix your issue.

They are pretty bad in a lot of areas. It took them years to get their Hybrid bunk door assemblies to the point they are not a huge leak and rot issue. Most towables are on a Lippert frame. Take a good look at all the welds sometime on a Lippert frame. They are the low bidder when they supply components so you know what your getting. The bad thing is you really have no choice except quit owning a trailer. Chances are you have something Lippert (Drew Industries) no matter what you have.
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Old 11-26-2015, 12:55 PM   #12
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My door (89.5"W x 83.5"H) weighs 19# when level with the floor. I had no way the measure but it takes about 40# pull to start its decent. Very well balanced I would say. Absolutely no sign of the problem.
WW
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Old 11-26-2015, 02:19 PM   #13
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Kark4Kat - How many springs on your door?
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Old 11-26-2015, 02:44 PM   #14
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door/higne pin

It's the door that's the problem from what I can see. The alum is a poor grade. I would beef it up on the outside with an alum strap of 6061 alum across the miter joint extending about four or five inches up the door with SS screws or rivets to prevent any further damage to that joint.

Mike
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Old 11-26-2015, 06:29 PM   #15
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Kark4Kat - How many springs on your door?
Same as yours.

As to having components by Lippert, yes there is no avoiding it. Everything is Lippert. Windows, entry doors, ramp doors, frames, slide mechanisms, entry steps, pinboxes, suspension components, etc. They own the industry.
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Old 11-27-2015, 06:51 PM   #16
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andy29847: The door is nearly weightless - up and down with one hand.

Same here w/o railings attached.

With the railings attached I cannot put the door up w/o help.

I'm thinking like aviator42 for preventative measures.
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Old 11-27-2015, 07:02 PM   #17
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Kark4Kat - How many springs on your door?
Do you have a party deck ? seems like a lot of springs
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Old 11-27-2015, 07:22 PM   #18
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No party deck. There are 6 springs. That seems to be normal. I do not know if Forest River has springs of different strengths for standard doors vs. party deck doors.

I am waiting for a response from the Lippert Engineers. I hope they will make the door good. If they won't cooperate, I think I will remove one spring and see how the door works. I also have an idea for spreading the hinge load over a larger area.



My toyhauler was bought new in April 2013. The door was changed out June 2015.
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Old 11-27-2015, 08:01 PM   #19
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I do indeed have the party deck. Maybe the added layer or metal in the door and the rails add enough weight to make a difference...
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Old 11-27-2015, 08:16 PM   #20
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I can see added springs for the party deck as it would be a heavier door .
My door on the 29 xlr only has 3 springs and operates very easy
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