Ramp door flex - hinge line

[andy29847]

The original ramp door on my toy hauler failed at the hinge line. Lippert looked at my pics, said the failure was caused by water damage. The door was replaced 6 months ago. I am watching it very closely. These doors cost a lot.

I have noticed that there is a considerable "flex" at the bottom of the door when it is opened. Have any of you other toy hauler owners noticed the same thing?

New door


Looks OK when closed


Inside pic when open


Outside pic when opened

[Mr Havercamp]

Another fine LCI design..... taking about 10 minutes to weld those mitres, and maybe add a reinforcement plate must have been to expensive.

[WolfWhistle]

It seems that weight on the door would bend the mitred joints the other way. I agree, the mitres should have been welded... if possible.

I ran out and checked mine (ok, so I walked) and all is straight and true.
WW

[andy29847]

Wolf Whistle - the weight of the door is suspended in air by the pressure of the springs against the hinges.

[WolfWhistle]

Originally Posted by andy29847

Wolf Whistle - the weight of the door is suspended in air by the pressure of the springs against the hinges.

Make sense. Its the weight of the door that has cause the joints to bend / pull apart and not a the weight of a toy being loaded. Wow
WW

[18CrewDually]

I agree the spring is causing the issue along with lack of structural fastening of the aluminum trim.

I think if the spring was on the other side of the chassis hinge (more towards center) it may help.

[andy29847]

There are six springs across the hingeline -


The deflection is the same on both sides -


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.

If the springs were weaker, the door might not be manageable (dangerous to open or close).

[WolfWhistle]

I wonder: when lowering the ramp, how much weight are you feeling? Wonder if the total spring assist is too much / more than necessary? I will test mine and let you know about how much weight I have to take.

Also, on your unit, could they hinge pins be binding? This would be difficult to prove.

The hinges, springs from Lippert are on thousands of units and I have to wonder if others are having this issue. But more importantly, that they will take care of your problem.
WW

[andy29847]

The door is nearly weightless - up and down with one hand.

The hinge pins are not binding.

I have the same question about other doors. It is not something easily noticed. Web info seems to indicate there was similar problems in 2009-2011. Not much recent info posted.

[Karl4Cat]

I wonder if your springs are stronger than mine causing the issue? My door is moderately heavy with two hands. Not bad but certainly not weightless.

[Mr Havercamp]

Originally Posted by andy29847

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.

[WolfWhistle]

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

[andy29847]

Kark4Kat - How many springs on your door?

[aviator42]

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

[Karl4Cat]

Originally Posted by andy29847

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.

[dwhit]

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.

[northstar1960]

Originally Posted by andy29847

Kark4Kat - How many springs on your door?

Do you have a party deck ? seems like a lot of springs

[andy29847]

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.

[Karl4Cat]

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...

[northstar1960]

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