Aluminum Camper Forum

General Category => News and Announcement => Topic started by: ADR on October 26, 2018, 01:12:44 PM

Title: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on October 26, 2018, 01:12:44 PM
Yikes!

Safety Issue Type: Recalls
September 19 2018 NHTSA Campaign Number: 18V643000
Drawbar may Crack and Trailer may Separate
If the trailer separates from the tow vehicle, it can increase the risk of a crash.
NHTSA Campaign Number 18V643000
Manufacturer Livin' Lite Recreational Vehicles
Components STRUCTURE
Potential Number of Units Affected 154
Summary
Livin' Lite Recreational Vehicles (Livin' Lite) is recalling certain 2017-2019 Livin' Lite CampLite
travel trailers, models 21BHS, 21RBS, 23RKS and 23RLS. The drawbar of the trailer may crack
resulting in the trailer separating from the tow vehicle.

see attached PDF for more info.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Merlin on October 26, 2018, 08:15:28 PM
Thanks for the post.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Paul on October 27, 2018, 09:14:52 PM
i have a 2018 21BHS I wonder if it means mine is included in that recall? I guess I'll have to wait for the letter
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on October 28, 2018, 07:30:24 AM
There is another doc that is linked in the PDF about the recall-

It reads >

"The frame design of the trailer changed. Trailers built prior to the recall population do
not exhibit any of the issues associated with the recalled trailers. All redesigned
trailers are included in the recall population.
Production Dates : SEP 28, 2017 - JUL 09, 2018
VIN Range 1 : Begin : 56DTW2126J1050793 End : 56DTW2129J1011485"

It appears ALL 21's and 23's built between the above dates and vins have the issue.

In that document it states structural analysis was done and indicated a weakness>

"Chronology :
8/24/18 - Reports of units with cracks in the welds around the drawbar were received by Livin Lite.
8/27/18 - Structural analysis of the frame begins.
9/12/18 - Results of the analysis showed a weak area of the drawbar.
9/12/18 - Safety committee meeting was called where the consensus is to issue a recall."

Hard to understand why a company as large as Thor would not do a structural analysis on something so critical before they made a change and put it into production.

Could be interesting as I suspect very few RV dealers have the ability to weld AL properly in this rework.


Other doc linked below.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: JazzyPigsGA on October 28, 2018, 10:39:34 AM
Good clarification-dodged that since our production date was 3/2017. Timing was ok since Trailer is still waiting on parts from the accident sigh


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Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Apollo on October 28, 2018, 11:25:17 AM
Quote from: ADR on October 28, 2018, 07:30:24 AM


Hard to understand why a company as large as Thor would not do a structural analysis on something so critical before they made a change and put it into production.


Because thor does not care about proper engineering or anything important like that, they care 100% about reducing costs and increasing shareholder value.

I bet heads rolled in the corporate offices that they had to shell out for the testing and have to fix the trailers, someone's bonus is really going to be affected by this.

Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on October 29, 2018, 05:30:30 PM
Yep and this will cost them more than just doing it right in the first place.....

A letter to an owner has surfaced and it also says they will move the spare from the tongue to the back bumper.   Hmmm...wonder what they'll do if people already modified the back like I did- added an aluminum shelf made from a loading ramp- to carry my pair of Honda generators.


About 15 years ago I bought a car trailer rated for 7700lbs gross.   Got to looking at it and noticed the coupler was stamped 5000lbs gross max.
Called the manufacturer and they said "oh don't be silly it will be fine".
Told them I'd get the NTSB's opinion on that...all of a sudden they had a guy heading my way with a new coupler and all the mobile equipment to cut it off and weld on the new one :P
Turned out every one of the trailers at the dealer I bought from had the same issue. 
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Paul on October 31, 2018, 08:56:04 AM
Quote from: ADR on October 28, 2018, 07:30:24 AM
There is another doc that is linked in the PDF about the recall-

It reads >

"The frame design of the trailer changed. Trailers built prior to the recall population do
not exhibit any of the issues associated with the recalled trailers. All redesigned
trailers are included in the recall population.
Production Dates : SEP 28, 2017 - JUL 09, 2018
VIN Range 1 : Begin : 56DTW2126J1050793 End : 56DTW2129J1011485"

It appears ALL 21's and 23's built between the above dates and vins have the issue.

In that document it states structural analysis was done and indicated a weakness>

"Chronology :
8/24/18 - Reports of units with cracks in the welds around the drawbar were received by Livin Lite.
8/27/18 - Structural analysis of the frame begins.
9/12/18 - Results of the analysis showed a weak area of the drawbar.
9/12/18 - Safety committee meeting was called where the consensus is to issue a recall."

Hard to understand why a company as large as Thor would not do a structural analysis on something so critical before they made a change and put it into production.

Could be interesting as I suspect very few RV dealers have the ability to weld AL properly in this rework.


Other doc linked below.

My VIN is 56DTW2121J1101276   I think I am OK doesn't seem to be in the range your mentioned. But at the same time I am not sure since my trailer built date is within the range of SEP 28, 2017 - JUL 09, 2018   it was built in Oct 2017
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on October 31, 2018, 12:40:40 PM
Letters are showing up at owners now-  if you get one I guess you are in the bad range- if you don't- I'd call and confirm.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Merlin on October 31, 2018, 05:46:00 PM
Paul, Your "build date" may not be the same as a "production date". You also noted in other threads that your camper has the "old" style tank arrangement with both the shower and sink going into the gray tank. Right after yours was built LL went to the "new" style with only the kitchen sink going to gray and those campers may have included tongue design/build changes. For sure confirm with LL, but yours could be ok since the VIN seems ok?
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Paul on October 31, 2018, 10:20:04 PM
Quote from: Merlin on October 31, 2018, 05:46:00 PM
Paul, Your "build date" may not be the same as a "production date". You also noted in other threads that your camper has the "old" style tank arrangement with both the shower and sink going into the gray tank. Right after yours was built LL went to the "new" style with only the kitchen sink going to gray and those campers may have included tongue design/build changes. For sure confirm with LL, but yours could be ok since the VIN seems ok?

I'll wait for a letter and if I don't get one I'll call would be nice if mine is ok.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on November 01, 2018, 07:00:12 PM
With all the talk of cracked/failed welds I carefully inspected my 2018 16TBS today-
Found a crack at the junction of the "drawbar" and the frame :(
I marked it with a sharpie and will watch it for awhile to see if it grows.


Well that's odd- the site flipped the picture upside down....

Edit by Paul: I rotated the picture
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Merlin on November 01, 2018, 07:52:32 PM
Ack! That doesn't look good, whether or not it gets worse. Stress fracture in a high stress spot. Yuck. When Powder Hounds had their weld disaster last year I carefully inspected my camper. I guess I better do it again, paying special attention to the tongue/drawbar area.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Powder Hounds on November 02, 2018, 07:51:20 PM
Oh boy.... I feel the pain my fellow owners are going through. IMO, the dealers are not equipped to handle this situation. My dealer essentially washed their hands of this issue. LL had to transport my rig on a truck back to the plant for inspection. My field repairs must have met their standards as they did some minor rework but not much though. They almost sizzled some electrical wires but they did do what they committed to.

Good luck everybody!

The good news... just booked two months in an RV park near our local ski hill.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Paul on November 07, 2018, 09:50:48 PM
I got a little surprise by mail today! I will contact my dealer tomorrow but my Camplite is in storage right now. My dealer is 1000km from where I live so they'll have to find someone local!
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on November 08, 2018, 09:22:34 AM
That's too bad...

Looking at my 16TBS again I think I see a crack like the one I posted in the other side too- it is faint and harder to see. 
Going to play with some dye to see if I can confirm it.

I'd be very interested in seeing any pics of the 21/23 in that same area where the tongue is welded to the frame rails.  Wish I knew of one near me to look at.

It would have been so simple to weld an angled AL plate across the bottom of the marriage point between the two sizes.

Would not surprise me to see a recall eventually come on the 16's as well.  In fact I'm going to make sure the NHTSA knows about mine.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: dlb53151 on November 08, 2018, 11:58:30 AM
Apollo - you are spot-on.  This is not at all surprising. Thor is a publicly-held company.  They are ultimately focused on maximizing the stock price.  Erring on the side of oversimplifying this, they have 2 channels to do that - via increased pricing (without reducing volume) OR reduced cost.  The latter is generally easier especially in the short term.  Engineers are incentivized to take out every quarter nickel and penny they can, not on safety.  They have Corporate lawyers and product liability coverage with a manageable deductible to address that.  Preferred starting point is in areas that are "behind the walls and floors" where the typical customer won't notice.   Be an observer at an RV show and take note of how many people get on the ground to look underneath the trailers or the tongue area.  Very few.  Most are inside the trailers drooling like Pavlov's dog over the nice entertainment systems etc. 

Thor gobbles up companies like Livin' Lite to do cost-outs from synergies (1+1=3....).

Just look at their stock chart- stock price tripled from Jan 16 to Jan 18 and had pulled back since then due
to short sighted mismanagement which will only require more pervasive cost reductions. 


(https://uploads.tapatalk-cdn.com/20181108/eeaec1fac0270fc099b3e26ea7f1d902.jpg)l




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Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: charliem on November 08, 2018, 04:42:56 PM
PLEASE POST PICTURE. Can someone with a newer unit affected by the change and recall post a picture of the design problem? A picture backed off far enough  that I can see the newer design and the area of short coming. I would like to compare it to my older 21 tongue to understand the change. 
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on November 10, 2018, 08:15:05 AM
Below is a pic of the mod-  new 3x3 sq tube welded under existing tongue center member.

They also have the repair facility place an additional 2x4 tube on the forward side of the existing 2x4 bumper tube to accomodate some sort of spare tire mount for the rear bumper.

Haven't found a pic of the spare carrier yet...
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: DavidM on November 10, 2018, 10:36:43 AM
It looks like they left out the center aluminum tube in the A-frame structure. Stupid. Charlie, you have a center member right? Well that didn't come out quite right, but don't think too deeply about it :). Without that member and the cross members it has much less strength. The weld cracking was probably more to do with exceding the stress on the welds than poor welding.

Thor saved a few bucks by eliminating that member but probably cost them hundreds to repair it, not to mention huge inconvenience and costs to owners.

LL really did deserve to die under Thor's ownership.

David

Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: charliem on November 10, 2018, 12:51:59 PM
@DavidM , 
I was hoping you would weigh in on this and yes, I did have to read that second sentence twice. That said, I do have the continuous center member. It is a 3x3.5 tube unbroken from coupler to near the axles. The cross member sits on top of the longitudinal members so no butt joints under peeling stress. Thor's new design is just dumb and I'm not sure their fix accomplishes anything. @ADR (https://aluminumcamperforum.com/index.php?action=profile;u=595) 's drawing is unclear in that the left view shows a center beam extending rearward from the cross member but the right view doesn't. If the right view is correct and complete it just adds more butt welds. The added tubing should span the area at the base of the A where the cross member attaches. I now believe Thor's engineering department is only staffed by accountants and marketeers.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Merlin on November 10, 2018, 03:28:26 PM
This doesn't give me a lot of confidence in the design of my 16TBS either. If the left image in ADR's drawing is correct and the drawbar still failed, how is that different from the construction of pre-2017 trailers? Mine looks like that. This re-emphasizes the important of the cracks ADR found in the welds on his 2018 16TBS in the drawbar/frame area. Once again, I say "Ack!".
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on November 10, 2018, 07:27:46 PM
Guys that is not MY drawing- it is from an official Thor document.  :P
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: charliem on November 10, 2018, 07:30:48 PM
Got that. You're just the messenger. Not shooting at you.    ;)
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Merlin on November 10, 2018, 08:05:18 PM
Quote from: ADR on November 10, 2018, 07:27:46 PM
Guys that is not MY drawing- it is from an official Thor document.  :P

We all knew that and appreciate your posting it.  :) As soon as this light snow melts off my driveway, I'm going to carefully look at those spots circled in "your" drawing. Oops, I mean the drawing you posted.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on November 10, 2018, 08:33:42 PM
Yeah I'm thinking I'm going to have to remove the underbelly corrugated plastic to get a good look at ALL the welds. 
That will be messy as they sealed the penetrations with expanding foam...

As for the pic of the frame- didn't want anyone to think I was claiming "points"  for it- in fact I stole it from elsewhere ;D
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: djsamuel on November 11, 2018, 06:16:18 PM
That drawing is incorrect as the two views don't match. In addition I'm sitting by my camper (2013 21BHS) as I read this and can compare. The construction of my camper is substantially better than this design. The side pieces of the a-frame are the same size as the side beams running the length of the trailer. There is no reduction in size at that joint. In addition, the center piece is one continuous beam. It does not end at the most forward traverse beam. There are also gussets where the side a-frame beams are welded to the side beams. My question is, did they really eliminate that center beam leading to the hitch? I can't tell for sure by that drawing if they are installing a center beam to the hitch or beefing up an existing center beam by adding a second beam. If there was no center beam, that is inexcusable.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Paul on November 11, 2018, 06:29:26 PM
Quote from: djsamuel on November 11, 2018, 06:16:18 PM
That drawing is incorrect as the two views don't match. In addition I'm sitting by my camper (2013 21BHS) as I read this and can compare. The construction of my camper is substantially better than this design. The side pieces of the a-frame are the same size as the side beams running the length of the trailer. There is no reduction in size at that joint. In addition, the center piece is one continuous beam. It does not end at the most forward traverse beam. There are also gussets where the side a-frame beams are welded to the side beams. My question is, did they really eliminate that center beam leading to the hitch? I can't tell for sure by that drawing if they are installing a center beam to the hitch or beefing up an existing center beam by adding a second beam. If there was no center beam, that is inexcusable.

There is a center beam on mine so they must be beefing it up
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Firetruck41 on November 11, 2018, 09:53:57 PM
To me, it seems pretty clear that they are adding a beam for reinforcement, in the diagram.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: charliem on November 12, 2018, 12:38:05 AM
Quote from: Paul on November 11, 2018, 06:29:26 PM

There is a center beam on mine so they must be beefing it up
Paul, Does your center beam extend rearward almost to the axles? Mine (late 2013 build) has a single continuous unbroken 3x3.5 inch tube running from the coupler to near the axles. All cross members are welded to the side or top of the center beam. That's nothing like the Thor drawing. I'm still trying to understand the change they made and the fix they're proposing. Next time you're out in the cold Canadian snow take some pictures of the underside of your trailer  ;D .
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on November 12, 2018, 06:41:11 AM
Quote from: djsamuel on November 11, 2018, 06:16:18 PM
My question is, did they really eliminate that center beam leading to the hitch? I can't tell for sure by that drawing if they are installing a center beam to the hitch or beefing up an existing center beam by adding a second beam. If there was no center beam, that is inexcusable.

There is a center beam according to their drawings- they are beefing up part of it adding the new 3x3 piece under it from the coupler back to the crossmember.

Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on November 12, 2018, 06:45:23 AM
Here is a Thor pic of where the cracks are occuring on the side transitions from the frame to the tongue-
This looks EXACTLY like where my 16TBS is cracking
See pic in post #11 in this thread.  I posted that pic before I ever saw Thor's pic.....
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Merlin on November 12, 2018, 09:15:41 AM
Sure enough, that looks like the same place. Time to send LL a photo and contact the NHTSA.

I'm still not clear on how my 16TBS is different from your 16TBS (if at all), so I'll post some photos of mine too. No cracks on my 2015, yet.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Paul on February 12, 2019, 01:10:59 PM
I got the following instruction from my dealer. I need to find a local welder  because the dealer is 1000km away from me.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Merlin on February 12, 2019, 05:53:44 PM
And the dealer likely would not do the welding anyway! For any dealer that's almost for sure a contract job to a local aluminum welder. I hope you can find a good one in the Moncton area to get you fixed up.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Paul on February 19, 2019, 10:41:49 AM
Livin lite didn't wanted to ship the part directly to me so they shipped it to the closest dealer which is 88km or 1 hour away from me. They will receive the parts on Friday and I will most likely go pick them up on Monday and in May when my trailer is out of storage I will find a local welder to do the job. Would have saved me time if it was shipped directly to my house instead.

I hope the package is not too big!
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on February 19, 2019, 08:16:08 PM
My guess is around 6ft long....
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Paul on February 20, 2019, 10:18:42 AM
Quote from: ADR on February 19, 2019, 08:16:08 PM
My guess is around 6ft long....

Yeah that's what I am thinking too, I'll have to strap it down since I have the 5.5ft box or maybe it will fit in diagonal
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: surfsup1955 on February 22, 2019, 09:37:46 AM
Thanks for the info ADR and all!


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Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on April 27, 2019, 01:07:29 PM
Decided to look at my 2018 16TBS again-outside cracks have grown -  I had neglected to look at the inside- 
I sent an email to KZ on the 24th of April- will keep everyone posted what their response is.

The inside where the cracks are propogating up the reinforcement plate is particularly disturbing.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Whipfinisher on April 27, 2019, 07:09:15 PM
ADR, your weld pictures are sickening.  I hope KZ gets in touch with you quickly.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Merlin on April 27, 2019, 09:57:32 PM
Thanks for posting the photos ADR. Letting others know about the continuing weld defects could literally save lives. If you haven't already, use the NHTSA site at safercar.gov to report this.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on April 28, 2019, 06:33:47 AM

I'm estimating we have approximately 9000 miles on the trailer-  and I'm still within the 2 year bumper to bumper warranty.
We have a trip coming up in September that will be at least 4000 miles more on the trailer-  right now having discovered the additional cracking I would not do that trip unless this is repaired properly. 
That isn't an option.
If they don't promptly handle this I will get it reinforced and repaired prior to the trip- then go after them for the cost later.   

Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Paul on April 30, 2019, 09:03:15 PM
My recall was done today. The only thing I am not sure if we installed the gussets in the good location the instructions weren't clear and livin lite didn't provide much help when we called them, they only provided the diagram bellow.

The instructions says Gussets need to be welded in place on the sides of the main tube that goes through the bulk head. The placement of the gussets are on the backside of the first cross brace, and where the tube meets the third cross member of the frame. They are to be placed roughly a 40 degree angle.

So we removed the underbelly and installed the one at the third cross member. I did not took a picture of the gussets we installed under the belly but we took a picture of one we installed on the new 3x3 tube not sure if we were right I have a feeling we've put them at the wrong place now that I am reading the instruction again they should have been on the back side of that cross member (also under the belly) instead but I think we've put them in the frontside? You can see them in the last picture.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Paul on April 30, 2019, 09:10:02 PM
More pictures
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Merlin on May 01, 2019, 09:29:08 AM
Good work. Overall, it looks significantly reinforced and having the factory welds inspected is great. Have you moved the camper to your seasonal site? 
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Paul on May 01, 2019, 11:32:32 AM
Quote from: Merlin on May 01, 2019, 09:29:08 AM
Good work. Overall, it looks significantly reinforced and having the factory welds inspected is great. Have you moved the camper to your seasonal site?

It is currently in my driveway. My seasonal site open May 15. Can't wait!
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on May 01, 2019, 06:11:04 PM
Quote from: Merlin on April 27, 2019, 09:57:32 PM
Thanks for posting the photos ADR. Letting others know about the continuing weld defects could literally save lives. If you haven't already, use the NHTSA site at safercar.gov to report this.

Been trying!  The NHTSA website never will accept the forms I've filled out- complete the form- hit submit and after several minutes of a spinning "submitting" avatar I get  >

Gateway Timeout
The proxy server did not receive a timely response from the upstream server.
Reference #1.2c8eedcc.1556744724.28ecebd

Tried twice today- will try again tomorrow.

Gotta love our government..... :-\

EDIT- Never could get their online form to go through- they did email me a PDF to fill out- but you can't submit pictures.
So now they have emailed me back wanting pictures :P

Coincidentally I received an email from a warranty guy at KZ saying they will take care of it and do I know anyone who can weld ;D

EDIT- opened a case with the NHTSA.    Also waiting on KZ to ship the repair kit to a local welding shop.  I asked for notification when it ships and tracking info..so far nothing.


EDIT- this is getting frustrating- on May 6 I asked the warranty guy at KZ to let me know when the kit to repair would ship and please provide a tracking number.  I ask again on May 9.   Nothing.   Now another week has passed and still no kit, no word on when.   Very poor customer service.
The welding shop is busy and I need to get in line but I have to know when the kit will show up.   
I don't consider my trailer safe to travel as it is and I have places to go.


EDIT- this just keeps getting worse.  Tried calling the warranty guy on Fri May 17 and of course had to leave a message.
He calls back on Mon May 20 and appears to not know about my trailer and our previous email discussions.  He finally finds it in their system and says he doesn't know why the "kit" hasn't shipped but he'll find out "right now" and email me back. 
Now MAy 21 and no contact.
Meanwhile took the trailer down to the aluminum welding experts and we devised a plan to reweld all the cracks, and do a little reinforcing perhaps so I can use my trailer until KZ gets off their tails and sends the kit.

BTW the welding shop owner was astounded at how LL built the tongue- this guy has built many custom trailers and could not believe how they attempted to transition between the large frame sq tubing and the smaller tongue sq tubing with butt welds on aluminum.
We both wondered why they didn't just continue on with the same tubing size to the ball mount.   
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on May 24, 2019, 05:23:36 PM
Decided to post an extension to my last post-  I suspect since I did so many edits it never triggers as a "new post".
Another week has gone by with zero contact from KZ about the shipment of my repair kit.

I think the welding shop owner and I have figured out a better way to repair and reinforce than the "official" kit.   I really don't like KZ's plan- as I cannot mount the spare on the back as they intend- already have an AL platform there to carry my pair of Honda generators.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Merlin on May 24, 2019, 09:19:43 PM
Quote from: ADR on May 24, 2019, 05:23:36 PM
Decided to post an extension to my last post-  I suspect since I did so many edits it never triggers as a "new post".
Another week has gone by with zero contact from KZ about the shipment of my repair kit.

I think the welding shop owner and I have figured out a better way to repair and reinforce than the "official" kit.   I really don't like their plan- as I cannot mount the spare on the back as they intend- already have an AL platform there to carry my pair of Honda generators.

Good move to just git 'er done. Pro welders can do wonders.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on June 05, 2019, 02:15:47 PM
I think we see one reason the frames crack at the junction between sizes-   they did not weld the butt joint under the reinforcing plates.   
Should have been welded.
Then the weld under the plate would be ground flat removing part of it but the aluminum would still be fused due to the weld penetration.
THEN add the reinforcing plate over the entire area.
Haven't looked at inside yet- but it is probably the same.

Pic below is of no weld under reinforcing plate.

Oh- BTW I have received no further contact from KZ since the promise to call me back on May 20.   Of course the welding shop does not want to bill LL/KZ directly (don't blame them) so I'll have to pay and attempt to get it back.  We obviously are not using the LL/KZ "kit" since they never would ship it even after a month of asking.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on June 06, 2019, 07:39:44 PM
Got my camper back from the welding shop today- they welded the joint between the drawbar and main frame and then spanned all of it with 3/8" plate- very stout!
An email was also dispatched to KZ requesting reimbursement of the $400 charge for the work. For 5 weeks I tried to get them to send the kit, it never arrived and I couldn't wait any longer.   We'll see how that goes.

Below is a pic of the added reinforcement made from 3/8" plate- the frame tubing is only about 3/16"
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Merlin on June 06, 2019, 07:57:03 PM
I suspect $400 will let KZ off cheap because the parts+shipping+labor for their kit could easily be more than that. However, I doubt you'll ever see any money from them. I like that repair on your camper and I think this is another case where the next owner will get a better-than-factory camper from you someday.  ;)
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on June 06, 2019, 08:05:32 PM
Quote from: Merlin on June 06, 2019, 07:57:03 PM
I suspect $400 will let KZ off cheap because the parts+shipping+labor for their kit could easily be more than that. However, I doubt you'll ever see any money from them. I like that repair on your camper and I think this is another case where the next owner will get a better-than-factory camper from you someday.  ;)

I am still under factory warranty and I pointed out in my request for reimbursement that I tried for 5 weeks to do it their way and could wait no longer- we have places to go.   I have documentation of all the emails and phone calls with no resolution.
So we'll see....

What we really need is for additional 16TB/DB-S owners to file a complaint with the NHTSB- so far mine is the only one filed.   I sort of doubt it will be a recall with only one complaint but, who knows?
There are probably many of the 16's running around where the owners have no clue. 
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on June 15, 2019, 02:44:38 PM
Guess what showed up at the welding shop after 6+ weeks of trying?
A box with a rear spare carrier and a bunch of triangular aluminum plates.   That was all- no sq/rectangular tube.

A week or so back the warranty guy told me I need to do the full recall to get paid- so I asked "Are you saying my trailer IS under recall?"

He came back with "no I checked, it's not part of the recall so I'll submit your bill to be paid"

Then a week and a half later some of the recall parts showed up.....
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Merlin on June 15, 2019, 07:31:13 PM
Quote from: ADR on June 15, 2019, 02:44:38 PM
Guess what showed up at the welding shop after 6+ weeks of trying?
A box with a rear spare carrier and a bunch of triangular aluminum plates.   That was all- no sq/rectangular tube.

A week or so back the warranty guy told me I need to do the full recall to get paid- so I asked "Are you saying my trailer IS under recall?"

He came back with "no I checked, it's not part of the recall so I'll submit your bill to be paid"

Then a week and a half later some of the recall parts showed up.....

Thanks for continuing to post about this mess. I know it's a huge hassle for you, but at least it's been entertaining reading!  :o
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: DavidM on June 15, 2019, 09:03:03 PM
It has been entertaining. It shows how horrible, horrible, horrible Thor is at dealing with warranty/recall issues. Why anyone would want to buy anything from a Thor company is beyond me.

David
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on June 22, 2019, 04:04:40 PM
So last week a second box showed up at the welding shop with several 7' long pieces of aluminum sq/rectangular tubing...none of which appear to be the correct length.   84 lbs of it.

Question for Paul or anyone who had the recall done-   did the pieces KZ shipped come already cut to size?
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Merlin on June 22, 2019, 10:10:46 PM
Quote from: ADR on June 22, 2019, 04:04:40 PM
So last week a second box showed up at the welding shop with several 7' long pieces of aluminum sq/rectangular tubing...none of which appear to be the correct length.   84 lbs of it.

Question for Paul or anyone who had the recall done-   did the pieces KZ shipped come already cut to size?

Because it's happening to you, I suspect you can't see the humor in this. But it's a legendary story in the making. This should be written up when it's all done as an example of how awful some manufacturers are at recalls.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Paul on July 27, 2019, 10:51:25 PM
Quote from: ADR on June 22, 2019, 04:04:40 PM
So last week a second box showed up at the welding shop with several 7' long pieces of aluminum sq/rectangular tubing...none of which appear to be the correct length.   84 lbs of it.

Question for Paul or anyone who had the recall done-   did the pieces KZ shipped come already cut to size?

Sorry I just saw this now, they were already cut to size
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on August 02, 2019, 03:02:37 PM

After hounding the warranty guy at KZ for weeks my check for $400, what the welding shop charged, finally showed up TODAY :)

What an ordeal- at least it is fixed and they did eventually reimburse me.....

Have a major trip planned- leaving Labor Day weekend for what could likely become another 30+ day 9-10,000 mi trip.   
We'll see how the repair holds up.  Hopefully there will be no further issues with the frame.    8)
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: Merlin on August 02, 2019, 04:19:36 PM
Really! Ok, so I admit I was wrong 2 months ago when I wrote I thought you were unlikely to ever see any money from KZ. I guess pigs can fly.

Too bad you don't live close to me. I could use some of the big shipment of rectangular tubing you received to reinforce my bumper and tongue.

I hope your upcoming trip is free from anything coming apart that isn't supposed to.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: ADR on August 02, 2019, 07:27:50 PM
I too thought I might never see that check- I hounded them weekly about it though and I guess they gave in.
It has already done about a 300 mile trip- the real test will be the big trip out west we have coming up. 

I'm surprised no one else has reported the cracking on the 16's- but I suppose most people never look until the trailer drops in the road.

And really the NTSB only had a couple of reports on the 21's.

Spent yesterday moving my license plate holder/light up to the upper left corner by the clearance light.   My aluminum rack I put on the back was limited by the license plate on the left and the heater exhaust on the right.  Heater exhaust isn't a problem unless we run the heater but blocking that plate might have gotten me stopped some day.

BTW when I removed the clearance light to connect to the 12V wiring to it-   guess what?  1" diameter hole through the trailer skin for the wiring with ZERO caulking to weather seal it.....good thing there's no wood in this trailer or rot would have already started.
Title: Re: Camplite 17-19 21BHS, 21RBS, 23RKS and 23RLS Recall for failed drawbars.
Post by: DavidM on August 02, 2019, 09:44:05 PM
Quote from: ADR on August 02, 2019, 07:27:50 PM
BTW when I removed the clearance light to connect to the 12V wiring to it-   guess what?  1" diameter hole through the trailer skin for the wiring with ZERO caulking to weather seal it.....good thing there's no wood in this trailer or rot would have already started.

That brings up an interesting observation. Even though the workmanship probably deteriorated in the latter years of LL's existence, the lack of any organic material in the structure does overcome some of these deficiencies.

David