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Old 11-22-2015, 07:25 PM   #31
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I've posted it before but here is what the XLR GM said....
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Old 11-23-2015, 10:54 AM   #32
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This sequence of pictures shows the flex along the hinge line of my door. My door is less than 6 months old. I would like to hear if youse guys see similar distortion when your door is open.


door closed - no stress


door open pic from inside


door open - hinge line distorted
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Old 02-21-2016, 05:59 PM   #33
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Quote:
Originally Posted by andy29847 View Post
This sequence of pictures shows the flex along the hinge line of my door. My door is less than 6 months old. I would like to hear if youse guys see similar distortion when your door is open.
Same issue on unit I took delivery Dec2014. I believe the cause is the torque from the hinge springs, this twist is trying to close the door and it increases as the door opens further. The hinge plates attach to the doors bottom channel with two through-bolts. There is a third hinge bolt through only the deck itself - I can't see how this bolt helps much - a foam core with thin skins on each side cannot withstand much twist. Since the bottom channel is not welded to the side channels, the twist imparted by the hinges is resisted only by bottom channel's attachment to the door's core. This core to channel attachment is what is failing. The bottom channel is trying to twist off the door's core. I have carefully checked the hinge leaf on all hinges - they have slightly bowed, and the outside fiberglass is also bowing inward between the hinges.


Based the observations and prior postings it appears to me that perhaps removing the plywood from the door resulted in a composite structure unable to resist a torsion force, and this is aggravated by the bottom channel having an insufficient overlap over the core and its not being welded to the side channels. A deeper overlap and welding would transfer some of the torque force to the side channels.


It appears to me that the mechanical engineers at LCI frugged this one up.
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Old 02-21-2016, 06:10 PM   #34
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I should also add that I would think this to be more of an issue on the party-deck application.
When door is closed, spring torque is at its minimum.
When door is used as ramp, spring torque is at its maximum. But is for a relatively short time unless ramp is left down.
When door is used as party deck, spring torque is high - almost at its maximum - and the torque pressure is continuous. It is this continuous high stress which eventually causes failure.
It's got nothing to do with water - no wood.
It's got nothing to do with overloading the ramp (failure would be in opposite direction).

I would love to see Lippert take ownership publicly and offer some type of warranty repair. (Since I'm out of warranty, I dread getting into a non-winable pissing contest)
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Old 02-21-2016, 06:28 PM   #35
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FWIW, Lippert is going to replace my door. It's taking a long time, but they are paying. The new door was supposed to ship on FEB 5. It was still at Lippert on the 19th. I'm hoping that the door will be made differently. It wouldn't be hard ot make it stronger without spending a lot of money.
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