Originally Posted by andy29847
I think I have figured this out. I took a good look at my new door, including pulling some of the hinge bolts out. The actual door does not extend to the bottom 2 bolts on the hinges. The bolts just pass through the aluminum channel that seals the bottom edge of the door. I am going to make some pieces to try an beef this up.
FWIW, I have a dialogue going with Forest River about ramp door construction and the resultant downtime for my camper over the past 1 1/2 year.
I said: My ramp door failed. The aluminum channel around the outside of the door came loose and water got into the door. Lippert paid for the replacement of the door.
Six months later, the new ramp door was failing. Lippert again stood behind their product and replaced the door. My concern is that the new door is built just like the old one. The engineering for the ramp door is poor. The hinges are short. The hinges do not have a reinforcing plate inside the door (to tie the 3 bolts together). Only one of the 3 bolts in each hinge goes through the actual door. the other 2 go through the aluminum trim piece at the bottom of the door.
Forest River said: I have read your email and I am sorry to hear about the issues you have experienced. It appears that the majority of your problems have been with parts that our suppliers have provided to us. Indiana is the RV capital in the states, the majority of manufactures in the area we all use the same suppliers. Unfortunately, parts will give out which XLR has no control over, so I am really sad that you would not purchase another XLR or recommend to your friends. It sounds like the vendors have stood behind their product and Forest River has taken care of the warranty that was turned into us.
On the ramp door I am waiting for more information from our supplier to find out when your last ramp door was replaced. I’ve been told that they have changed the way they are made and want to make sure that yours is one of the newer. As soon as I find out more information, I will get back with you.
Lippert comments from the engineers:
1. The hinges are very short (compared to the length of the door).
Print 264968 (both current and previous REV H) shows a hinge length of 86.75” with an inside-to-inside extrusion width of 87.75.
2. Only one of the 3 hinge bolts go through the actual door material, the other 2 go through the metal trim. The core extends into the extrusion cavity- the 2 bolts per leaf in question are designed to go through both the core and the extrusion.
3. Also, there appears to be no mechanical bond between the bottom aluminum trim and the side aluminum trim. By design, there is a structural key in each corner that bonds the door together using high strength structural adhesive.
These points all speak to the design of the door. If built to print and used as intended this door should perform as intended.
I replied to Lipperts statement: The number 86.75" that the engineer used must be referring to the width of the full hinge line (7 hinges - matching the width of the door). When I say the hinges are short, I and talking about how far up the door they extend.
I pulled out the 2 lower bolts on my hinges. The cavity between the holes in the aluminum was empty.
About the structural key bonded with high strength adhesive, I can't say yes or no on that. However, given that the doors are failing, and they start to flex as soon as they are used, whatever is in there is not doing the job.
To prove my point on number 2, I removed a bolt and sent pictures showing the bottom of the door is hollow:
Waiting to hear back from Forest River/Lippert now.