Bent front frame cross-member on '07 Solaris T-2499

[Trailblazer]

Well it seems like Sunline is not the only manufacturer having some frame issues. Check out this link in another forum

http://www.rv.net/forum/index.cfm/fu...d/21956906.cfm

[Poppy & Nana]

Well as some of you know, Leo and I had a slight mishap with an unpaved road just before the Adirondack M&G.

Our local welder had taken a look at our frame and did not find anything unusual.......however after the "mishap" our frame definitely showed MAJOR damage - that being the header of the A frame.

Well we took it to our local dealer (former Sunline dealer) and his comment was "NO WAY"....he did refer us to a local welding shop...Leo dropped off the TT about 2 weeks ago and unfortunately never mentioned the bent frame issues with the 2499. Yesterday we stopped by to see if any work was being done on it and unfortunately none was....BUT....I did have a change to speak with the owner and told him about the problems....gave him Lippert's phone # and the welder in Rochester who had done the work for another member on the forum. Anyway he told Leo to stop by this morning around 10 and it should be finished....yea right.....OK Leo called around 3:15 and said he was on his way home, I asked how's it look and his comment was Wayne (of Wayne's Welding) was more concerned about my reaction to the repair...(gee I don't understand why)...so an hour later and Leo is home. What a job it looks great.....unfortunately I don't have time to take photos before it goes to storage in the morning, but I promise to do so in the spring!

It looks like he removed the enite header and replaced it with a 6" channel piece which looks VERY thick! - he cut the header to fit the A legs and welded pieces below the cut.

I am very happy with the work and it looks stonger than anything I've seen!

Sad to say the TT is going into storage , we managed to get everything done tonight when Leo got home...it took us about 2 hours to get everything done...including doing all the linens and vacuum sealing them for next year.

[Poppy & Nana]

I managed to get some photos of the repaired frame before we put the TT into storage....now I'm not a photographer, so please bear with the photos!

[LarryJ]

Thanks to you guys, I checked my T-2499 front and found the same kind of bend in the front crosspiece. My 2006 trailer manufactured in Aug, 2005 has about a 1-2" bend at the location of the battery switch. The cross piece is 6 1/2" high but definitely a lighter metal than the Ibeams. The aframe is 4". I have contacted the dealer I purchased from (Restless Wheels, Manassas, VA) and waiting to hear from them. I will try to attach my picture (process seems too hard) showing the bend. Will let you know the fix and cost.

[rwhyne]

I'm new to the club, but after reading all of the posts about bent frames on the 2499 I took a look at mine and if I didn't know better I'd say that some of those pictures are from my 2007 model. Same problems that others are writing about are the ones I'm eperiencing - now I known why the batteries were slipping through the support brackets, I thought that they had "bowed" and not the frame.
We too searched for 2 years before deciding on a Sunline and this particular model. We love it, but the obvious frame defect really does sap some of the joy out of ownerhsip.

[kanyonkitty]

Robert & Larry,

Sorry to hear that you are also caught up in the lippert frame mess. But, it is fixable. Upsetting to say the least, but I (we) still have one of the best darn COACHES produced.

[Sunline Fan]

Originally Posted by kanyonkitty

I (we) still have one of the best darn trailers produced.

KITTY!!!!!!

You of all people!! I can't believe it!!

[Hematite]

LarryJ and Robert:

It seems like a daunting problem, at first, but it really isn't. If the crosspiece hasn't been bent too much that it is broken, take it and have the crosspiece straightened and reinforced. Mine was bent once but I had the Sunline put on an alignment rack at the dealer and straightened perfectly straight before it was welded. That way I was assured that the mainframe and A frame were totally straight and aligned to each other. Then the crosspiece was stripped of everything and a 2x2x1/4" angle was welded between the A frame and to back of the header making a pretty indestructible but (relatively) light repair. The gas pipe was routed higher as was everything else on the header. They also replaced the front battery crossmember with a 2x2x1/4" to stop frame twist by the Reese twin cams.

I would caution about adding excess amounts of steel to repair the condition. The "if a little is good, a lot is better" train of thought is not only unnecessary but brings its own problems to the situation. The dealer that did my job was aware that the 2499 has a VERY heavy tongue weight and was very thoughtful to repair it so it could never happen again but not add a ridiculous amount of weight to do it. Another consideration is that the more metal that you add, the more welding that is done which adds frame heat fatigue as a possibility. If Sunline had stuck with the 10 gauge header instead of trying to lighten it with the 12 gauge one the problem may never have happened.

[kanyonkitty]

The truth, Jon, only the truth. I WAS majorly upset when I had the problem, being on a fixed income, but all should (crossed fingers) be well now

[Sunline Fan]

Originally Posted by kanyonkitty

The truth, Jon, only the truth. I WAS majorly upset when I had the problem, being on a fixed income, but all should (crossed fingers) be well now

No Kitty, see my underlined part. We own COACHES, not trailers .

Jon

[precorguy]

ok, just a quick question on this frame issue

i have been watching the header on my 2553 and so far - there is no twist/bend and we have done some travelling this year and been in some bumpy groupgrounds.

given this, i have done nothing to the frame to strengthen the header -- but have been tossed about adding a small steel box beam.

has anyone had this problem on a 2553 or just the 2499?

i just don't know what i should do????

[Hematite]

precorguy:

Look at it this way, if your Sunline has the thinner header, it will give you piece of mind to have it reinforced. The big plus to doing it now is that it wil be WAY less costly to do it while the header does not need to be straightened.
I think that the thinner header with heavy tongue weight is the real issue. The addition of an unusual circumstance on the road, and you have the problem. Ultimately, it will be your decision about whether to add a reinforcement. I would say that given the thinner header, it would be prudent to add a light reinforcement, but that's coming from someone that had the header bend.

[LarryJ]

Update - my RV dealer straightened the header, welded angle to the header to reinforce it, and welded C channel between the aframe and the coach rails, looks very solid, service manager said he would warrant it for the life of the coach. Around $450-500 (had other stuff done as well), estimate was for 5 hours of labor. I'm happy to have the problem taken care of....

[henryj]

LarryJ, good to hear of another successful fix. I hope you'll find some nice fall weather to enjoy it yet. Our 2499 has been winterized for several weeks and we actually have snow on the ground right now.

Also, welcome to the Sunline Owners Club and glad we could be of assistance.

Henry

[SanDimasJoe]

LarryJ,

Would it be possible for you to post some pics of your tt tongue fix? Sure would like to see the repair.

Thanks Joe

[LarryJ]

Repair was done by straightening the crossbar, welding 3x1 c/tube steel between aframe and Ibeam (both sides, continuous weld) and backing the crosspiece with 2x2 angle (spot) .



http://www.flickr.com/photos/14036526@N06/2999895875/

Tried to attach picture here(its in a public area on Flickr). Repair looks pretty solid, see how it holds up.



Need a forum gurus help with pictures, I guess. Also put the repair photo in this site's photos.

[MACK C-85]

I right clicked on the picture, then opened PROPERTIES, in the middle of the box there is a URL: copy everything from "http: to .jpg" leave off the stuff after .jpg. Click the Img box, paste the URL, click the Img box again.

It is not the same URL that is at the top of the FLICKR page!!

[rwhyne]

I just made arrangements with Lippert frames to have my T2499 repaired. I live about 2 hours away from their PA plant and I'll be dropping off the trailer for them to repair. I've read through these past posts and this is the second time that I've responded - I took pictures and sent them to Lippert, was in contact with someone named Dave and we've been eamiling back and forth making arrangements for me to get the trailer to their plant. I figured that since they built the frame (as per Sunline's specifications) they would have better understanding of the issue and the necessary skills to properly repair the damage. I was told the work (as illustrated by the photos I sent) should cost about $300.00 - we'll see, but whatever, I want to keep this trailer for another season at least and the repair cost should be worth it - I hope.

[JohnB]

Robert

First off, welcome to the club.

You have a T2499, one of the heavy tongue ones. When you get your camper back it would be great if we could see how it was corrected.

If possible please take before and after pics. These really help tell us a lot.

Good luck and again welcome.

John

[rwhyne]

John,

I'll try to post some pictures of the before and after repair but I'm not sure of the procedure since I'm new to this forum. I'll look around but if anyone out there can help with some instructions I'd appreciate it. Thanks.