frame issues again

[ikoolu]

For the 2nd time we have major issues with of 2020 ultra lite frame. The first time the welds broke on the frame after the A frame lounge connection right near the front grey water tank drain valve on both sides. After a 4000 mile rv trip the last morning i noticed the front sagging alot and sure enough found the broken welds. $800 bucks later and hours waiting for a portable welder to show we got back on the road and home. Yesterday 18 months alter and 1600 miles we pulled in the rest stop and i thought its been a while i better check the frame. This time the welds we had repaired were ok the actual i beam broke and cracked about 1.5 inches of the actual top of the beam. Again went under the other side and yep the repaired welds held the damnb steel i bean crack 2 inches along the top flag part. Crap the trailer could have broken lose and killed us or another driver. Another 10 hours waiting and watching a great portable welder that actually fabricated custom gussets to butter up to the i beam from top to bottom 4 inches wide out of 1/4 steel. We added a 1.5 round steel tube in front of the i beam cross brace to help with any twisting. we still have 1400 miles a d few days to get home - hopefully no more issues. So this covid made frame by Lippert just a one off or was it cheep Chinese steel and goofball employees who thought they were welders assembling the frame? Or was it the WD hitch causing stain some how? And of course Lippert says it's not their fault and rockwood says its not theirs and insurance says your deductible must be met. Any others have frame issues?

[Oaklevel]

Have you weighed the rig. The other possibility is that you are overloaded.

Good Luck!!

[ikoolu]

Originally Posted by Oaklevel

Have you weighed the rig. The other possibility is that you are overloaded.

Good Luck!!

Of course under tongue weight and total weight. Hardly carry anything in basement but a couple crates for sewer hoses, cables and alike. Cary the chairs, tools in the truck bed. Tow with just a 1/4 tank oof fresh water and that tank in behind the rear wheels.

[trailerdude]

What model trailer is this?

[ikoolu]

Originally Posted by trailerdude

What model trailer is this?

2606WS

[D W]

Pictures would be nice, otherwise everything is just a guess.

[ikoolu]

well the repairs are done and i primed and painted the gussets - i was wondering if others have have from /broken weld issues.

[NMWildcat]

Originally Posted by ikoolu

well the repairs are done and i primed and painted the gussets - i was wondering if others have have from /broken weld issues.

Do a search on RV lite frame problems. You are definitely not alone. Just one of the problems caused when manufacturers try to lighten the RV so it can be pulled by smaller vehicles.

[ikoolu]

Originally Posted by ikoolu

well the repairs are done and i primed and painted the gussets - i was wondering if others have have from /broken weld issues.

[QUOTE=D W;2938714]Pictures would be nice, otherwise everything is just a guess.

[Cabinfever97]

I agree. So many issues are caused by light weight materials being used. It's usually not to save cost but to save weight. Weight balance, or lack of, at times can be blamed on 1/2 ton towable units. I have noticed some fresh water tanks seem to be too far rear for proper balance. My guess is to keep tongue weight light for GVWs on 1/2 tons. Keep the tongue weight as close to minimum as possible.

[Bob K4TAX]

I agree that lighter-weight trailers use lighter-weight materials. In some cases, I fear reducing structural integrity. Now with all the welding, added gusset plates, added bars, and such, how much weight was added to the trailer? This changed the dry weight but DID NOT change the maximum gross weight, but it did reduce the cargo weight.

Someone already asked about weight and balance. These items are VERY important and the only real way to know is to put the trailer loaded for camping and the tow vehicle on CAT scales and get the real numbers. These are very important. Guessing and saying I know I'm not overloaded is not valid. Even loading near-maximum load for the trailer is sometimes questionable.

A second point, our highways and roads are rough. There are no two ways about it. Some are very rough and the bouncing puts stress on all pieces of equipment, materials, and welds. One state we traveled through, I commented that their interstate was mostly potholes with a little pavement in between. In this case, the only choice is to slow down. I've seen vehicles towing trailers on these roads and the trailer is bouncing around like tin cans on strings behind the newlywed vehicle. Just gotta slow down to take care of the equipment. Those behind you can wait or wait for an appropriate place to pass.

Schedule is not important, arrival in one piece and with everything working is important.

Bob

[ikoolu]

Not going to get into a discussion about weight - i know what i carry and the weight - this is not my first trailer. The frame i beam broke not at the a frame where the tongue attaches to the frame but 4 feet back - the actual top of the I beam broke from the beam and cracked about 2 inches long - the first time the weld cracked there not the beam itself broke - that not over weight on the hitch thats inferior materials or just just to light of a frame - its only 1 /8 steel there. The tongue frame i tube channel - the frame the trailer sits on is either c channels or I beams both are very thin. towable frames are thinner and lighter and IMP not made for properly. I am not off roading and the farm frame actual breaks? Again i started the thread too see if other with Forest River products have had the similar issues. The internet is loaded with shackles breaking and other support member at axles - but my issue 3-4 feet in front of the ankles on the I beams not the C channels or tongue framing.

[Mandog]

Sorry that’s happening, I fabricate and weld at my shop but not as a some living, Unless you have a unique situation that puts stress on the frame like a steep driveway or hard turns the fram shouldn’t fail. Stay on lipert as they are responsible. They make the frames thin and hard which can make them more prone to stress cracks.
I’d make sure your WD bars aren’t bottomed out in turns, tires don’t have to much air in them and suspension is all good. If so it’s faulty manufacturing! A good welder fabricator can strengthen it if it continues to give you problems!

[ikoolu]

Originally Posted by Mandog

Sorry that’s happening, I fabricate and weld at my shop but not as a some living, Unless you have a unique situation that puts stress on the frame like a steep driveway or hard turns the fram shouldn’t fail. Stay on lipert as they are responsible. They make the frames thin and hard which can make them more prone to stress cracks.
I’d make sure your WD bars aren’t bottomed out in turns, tires don’t have to much air in them and suspension is all good. If so it’s faulty manufacturing! A good welder fabricator can strengthen it if it continues to give you problems!

dumping the WDH already - we live on flat land and store it on a level pad. The welding the guy did was great i might have a couple more angle iron supports added along the frame before our 6k trip this fall. Lippert has blown me off already - will chat with the insurance comp y about the repairs but i guessing i wont get a dime. Just a shame -