What a horrible experience for you and your family. You asked for some thoughts on this.
First, call Gregg Rollins yourself. It sounds as if there is some loss of communication between FR, the local dealer and you. If it hasn't been posted here previously on this thread, Gregg's contact info use to be (574) 642-2640 ext. 225. E-mail: firstname.lastname@example.org
. I understand he responds quicker to email. In fact, I would do everything via email and letter to create a paper trail.
It doesn't seem right that the dealer and FR says to pay again to fix these repairs. You say that FR told the dealer that they wont do anything more? This sounds odd.
Connect with Gregg yourself. I've never heard of such a shoddy repair job being done at the factory. Usually people have found the factory went above and beyond their expectations. There is something going on here.
Newbold1, the US lemon Laws do not apply to campers as I understand it. Not an attorney, but each state has their own laws and the federal government has the Magnusson-Moss act. But, in general, lemon laws may apply to RVs with motors but not campers. Like I said, though, each state is different.
The advice to seek legal counsel might be required here. Consider the legal route. A letter on your attorneys letterhead will often open doors and grease the wheels.
Best of luck to you.