[QUOTE=zoomer32ca;639326]This is our second summer with our 2014 Roo. We have had a number of problems with our bunkends leaking, had the front bunkend replaced at the end of the summer and now problems with the latch system.
The bottom of the latch system at the handle literally exploded today when trying to close the bunk. As you know, it is a plastic system that is unlikely to last more than a few seasons. The system is held together by little 1/2 inch rivet like things that are pressed into the plastic. (I wish I could show you a picture of one, but mine shot out like bullets when the system came apart).
Thought for a second about calling my dealer, but from my experience they are either incapable or unwilling to do quality work. I came up with a solution that will undoubtedly outlast the rivet system.
I used a 1/8 inch drill bit and drilled through the handle. I drilled part way from both sides as there is a collar on both sides that the arms fit into (did not want to damage the collar). There is only about an 1/8 - 1/4 inch of plastic to go through because of the holes for the rivets. I purchased #4-32 x 1 1/2 inch stainless steel machine screws and nuts and installed them straight through. I clipped the end of the screw, filed it down flush and added a little silicon to help hold the nut in place.
This happened in my driveway, if we had been camping and packing up there is no way we would have been able to hold the door closed. I purchased enough materials to do all the latches as they break. Will carry all the tools to make this repair anywhere.
I have already had to push one of the rivets in the top of the mechanism back into place. I think the same solution would work for the top three rivets just with shorter screws.
Was there a reason you had to use silicone to try to keep the nut tight? Why couldn't you use a nylon lock nut?