The Heartbreak of Delamination

[Chiefblueman]

Just returned from a 3 week trip when I noticed this while cleaning up and inspection of roof and seals and such. It appears the sidewall of the trailer is delaminating above the curbside dining slide on my 315RLTS. These spots pretty much covered when the slide is shut and hard to see even when the slide is open. These seams have been visible since new but were not raised to any degree. I don't consider being able to see a seam a problem, especially on a warm day. This particular seam has raised about a quarter of an inch. I'm able to push it back in and I can hear what sounds like glue trying to hold it when I release it. My spirits have taken a nose dive.

There is no sign of any damage or water intrusion on the interior. The exterior issue is directly in line with seam tape on the interior of the wall. We have never had any water intrusion to the interior of the unit. I did have a plumbing leak under the kitchen but that simply dripped onto the mylar insulator and coroplast and ran out.

I have been diligent in keeping all the roof seals in good shape. I have used only the prescribed Alpha Systems sealants. BTW, the first question from CS rep asked was which brand of sealant have I been using.

The trailer is less than 3 years old and should be covered by the structural warranty I have contacted Grand Design customer service and received a case number. Photos and a video have been sent. GD wanted me to take it to a dealer but I asked if I could take it to an independent that specializes in repair and service and doesn't sell RVs and was given the OK. Have an appointment for Oct 10 to have the damage inspected and a report for GD. GD has handled my previous issues in exemplary fashion, one of those issues pretty significant. I hope that level of customer service still exists.

I have to say, I'm becoming a bit weary of having issues with this trailer. As an electrician and pretty fair mechanic, I can take care of most problems with an RV but this unit is wearing me out. This past trip I let out a sigh of contentment, thinking I'd finally gotten most of the bugs worked out. Well, except for that cricket that hopped into the front storage, finally chased him out after a couple of days.

 

[backtrack2015]

I’m sorry to see and hear this. Hopefully it all gets handled well by GD.

 

[Canyonlight]

Kim - sounds like a situation GDRV will take care of for you especially under the 3 year warranty. They have been pretty good about taking care of those who take care of their units as prescribed in the Owners Manual and it sounds like you have.

I recall that sinking feeling when hearing that "snapping and popping" of the side wall as we found it last fall. GDRV took great care of us this spring not only replacing the side walls but addressing other things we had on our list as well as they taking care of things they encountered.

Keep us posted.

Dan

 

[Chiefblueman]

Kim - sounds like a situation GDRV will take care of for you especially under the 3 year warranty. They have been pretty good about taking care of those who take care of their units as prescribed in the Owners Manual and it sounds like you have.

I recall that sinking feeling when hearing that "snapping and popping" of the side wall as we found it last fall. GDRV took great care of us this spring not only replacing the side walls but addressing other things we had on our list as well as they taking care of things they encountered.

Keep us posted.

Dan

Thanks, Dan. GD customer service has responded today just to let me know the info and pictures I sent have been received and to let them know what the repair service finds. I'm encouraged by their responsiveness.

My hope is that they replace the sidewall as they did in your case. I would not be looking forward to a winter trip from the Northwest but a Spring trip could actually be fun. I'll keep you posted.

 

[kevinpo]

Kim,
Sorry to read your post I hope everything works out to your satisfaction in the end and you don't become too discouraged. It's a lot of time and effort on your part to keep it road worthy. It's not like you have an old unit that wasn't taken care of. Good thing you caught it early before the real rains start in a few weeks.

All the best,
Kevin

 

[MidwestCamper]

View attachment 15316View attachment 15317View attachment 15318View attachment 15319

Just returned from a 3 week trip when I noticed this while cleaning up and inspection of roof and seals and such. It appears the sidewall of the trailer is delaminating above the curbside dining slide on my 315RLTS. These spots pretty much covered when the slide is shut and hard to see even when the slide is open. These seams have been visible since new but were not raised to any degree. I don't consider being able to see a seam a problem, especially on a warm day. This particular seam has raised about a quarter of an inch. I'm able to push it back in and I can hear what sounds like glue trying to hold it when I release it. My spirits have taken a nose dive.

There is no sign of any damage or water intrusion on the interior. The exterior issue is directly in line with seam tape on the interior of the wall. We have never had any water intrusion to the interior of the unit. I did have a plumbing leak under the kitchen but that simply dripped onto the mylar insulator and coroplast and ran out.

I have been diligent in keeping all the roof seals in good shape. I have used only the prescribed Alpha Systems sealants. BTW, the first question from CS rep asked was which brand of sealant have I been using.

The trailer is less than 3 years old and should be covered by the structural warranty I have contacted Grand Design customer service and received a case number. Photos and a video have been sent. GD wanted me to take it to a dealer but I asked if I could take it to an independent that specializes in repair and service and doesn't sell RVs and was given the OK. Have an appointment for Oct 10 to have the damage inspected and a report for GD. GD has handled my previous issues in exemplary fashion, one of those issues pretty significant. I hope that level of customer service still exists.

I have to say, I'm becoming a bit weary of having issues with this trailer. As an electrician and pretty fair mechanic, I can take care of most problems with an RV but this unit is wearing me out. This past trip I let out a sigh of contentment, thinking I'd finally gotten most of the bugs worked out. Well, except for that cricket that hopped into the front storage, finally chased him out after a couple of days.

Chief,
I just had the same issue repaired on my Imagine as in Pic #4 . The issue occurred at two vertical supporting members above the slide and was the result of the luan joints bulging. They cut out the sections in the middle and re-bonded the material back in place, and re-painted. I too am getting tired of working on this rig but I do really like it. I need some future reliability to get out of this love/hate relationship. GDRV has done a great job in taking care of me but once this thing is out of warranty....what next??

Correction: There are no vertical members above the slide but two horizontal aluminum box channels.

 

[Chiefblueman]

Took this photo today.Looks like there's more going on than I first thought. There looks to be 3 or maybe four spots above the slide. Removed the bulb seals for inspection and 303 treatment. The bulge has pulled the seal track away from the sealant and the track is drooping a little. I can see behind the track and can get a finger back there, can feel the space between luan and the aluminum framing. There is no sign of water intrusion that I can see. The track is sealed along its length except where the major bulge is. I placed some Gorilla tape over the gap to keep water out. Fortunately the trailer hasn't seen rain in over a month.


I just told my wife about the situation. She reminded me of one day last week when we were in La Pine, OR when we both heard a "pop" from the dining slide area. She asked me if it was the slide settling at that time. I said nah, must've been a pine cone or something. I wonder if the glue let go at the most prominent site. I'm all over the trailer pre trip, always check the roof and seals. I've noticed the one spot before but it was just a visible joint, couldn't feel any raised area.

Thanks for the encouragement. We really love "camping" in this very comfortable and spacious trailer. My plan was to own it for 10 years, hope it works out!

 

[Aridon]

The pop could of been anything. Unlikely it had anything to do with the delamination.

Looks like the adhesive they used is letting go. They should fix this without issue. Make sure you have a nice list of anything else you'd like them to look at while you are there.

Sucks, but when you have vacuum bonded walls it can and does happen from time to time. Glad you caught it inside of the warranty period.

 

[howson]

View attachment 15316View attachment 15317View attachment 15318View attachment 15319

Just returned from a 3 week trip when I noticed this while cleaning up and inspection of roof and seals and such. It appears the sidewall of the trailer is delaminating above the curbside dining slide on my 315RLTS. These spots pretty much covered when the slide is shut and hard to see even when the slide is open. These seams have been visible since new but were not raised to any degree. I don't consider being able to see a seam a problem, especially on a warm day. This particular seam has raised about a quarter of an inch. I'm able to push it back in and I can hear what sounds like glue trying to hold it when I release it. My spirits have taken a nose dive.

There is no sign of any damage or water intrusion on the interior. The exterior issue is directly in line with seam tape on the interior of the wall. We have never had any water intrusion to the interior of the unit. I did have a plumbing leak under the kitchen but that simply dripped onto the mylar insulator and coroplast and ran out.

I have been diligent in keeping all the roof seals in good shape. I have used only the prescribed Alpha Systems sealants. BTW, the first question from CS rep asked was which brand of sealant have I been using.

The trailer is less than 3 years old and should be covered by the structural warranty I have contacted Grand Design customer service and received a case number. Photos and a video have been sent. GD wanted me to take it to a dealer but I asked if I could take it to an independent that specializes in repair and service and doesn't sell RVs and was given the OK. Have an appointment for Oct 10 to have the damage inspected and a report for GD. GD has handled my previous issues in exemplary fashion, one of those issues pretty significant. I hope that level of customer service still exists.

I have to say, I'm becoming a bit weary of having issues with this trailer. As an electrician and pretty fair mechanic, I can take care of most problems with an RV but this unit is wearing me out. This past trip I let out a sigh of contentment, thinking I'd finally gotten most of the bugs worked out. Well, except for that cricket that hopped into the front storage, finally chased him out after a couple of days.

What a bummer of a post, Kim. Please keep all of us posted.

 

[Canyonlight]

Kim - Jerry McCarthy shared with me when I sent a video of our 3 areas that they were about 3 months out before they could get us in which would have been December. The beauty of the 1 minute video was being able to hear the snapping and popping and see the size of the area. I shared that it would be preferred to bring our 303 over in the spring and Jerry said what ever works best for us.

Also, I was concerned about how the overall RV would turnout after having both walls (and all three slide walls too it turned out.) After contacting Rob (Cate & Rob) who had walls replaced a couple or so years ago, Rob was simply amazed at how well things turned out. When Rob said this, I was totally at ease. Rob was right.......our 303 turned out better than new in and out !

As Rob and Jerry (and others on the forum as well) suggested, it is a good idea to spend at least one night at the GDRV campground before leaving just in case anything does come up so it can be fixed before you leave. We did have a couple items arise the first afternoon and next AM. Jerry's team was there W/I 10 minutes that first day PM as well as knocking on the door at 6 AM to next morning to follow up.

Carol and I were truly impressed at not only how all things turned out but at the responsiveness and friendliness of Jerry's team as well !

Dan

 

[howson]

View attachment 15339

Took this photo today.Looks like there's more going on than I first thought. There looks to be 3 or maybe four spots above the slide. Removed the bulb seals for inspection and 303 treatment. The bulge has pulled the seal track away from the sealant and the track is drooping a little. I can see behind the track and can get a finger back there, can feel the space between luan and the aluminum framing. There is no sign of water intrusion that I can see. The track is sealed along its length except where the major bulge is. I placed some Gorilla tape over the gap to keep water out. Fortunately the trailer hasn't seen rain in over a month.


I just told my wife about the situation. She reminded me of one day last week when we were in La Pine, OR when we both heard a "pop" from the dining slide area. She asked me if it was the slide settling at that time. I said nah, must've been a pine cone or something. I wonder if the glue let go at the most prominent site. I'm all over the trailer pre trip, always check the roof and seals. I've noticed the one spot before but it was just a visible joint, couldn't feel any raised area.

Thanks for the encouragement. We really love "camping" in this very comfortable and spacious trailer. My plan was to own it for 10 years, hope it works out!

What's the latest on this situation, Kim?

 

[Chiefblueman]

What's the latest on this situation, Kim?

Grand Design has determined this to be a warranty issue. I'm waiting to hear from them as to how they will effect the repair. Once things are more settled I'll give a detailed report. I don't like to go public with issues dealing with the factory until they are settled.

 

[MidwestCamper]

View attachment 15316View attachment 15317View attachment 15318View attachment 15319

Just returned from a 3 week trip when I noticed this while cleaning up and inspection of roof and seals and such. It appears the sidewall of the trailer is delaminating above the curbside dining slide on my 315RLTS. These spots pretty much covered when the slide is shut and hard to see even when the slide is open. These seams have been visible since new but were not raised to any degree. I don't consider being able to see a seam a problem, especially on a warm day. This particular seam has raised about a quarter of an inch. I'm able to push it back in and I can hear what sounds like glue trying to hold it when I release it. My spirits have taken a nose dive.

There is no sign of any damage or water intrusion on the interior. The exterior issue is directly in line with seam tape on the interior of the wall. We have never had any water intrusion to the interior of the unit. I did have a plumbing leak under the kitchen but that simply dripped onto the mylar insulator and coroplast and ran out.

I have been diligent in keeping all the roof seals in good shape. I have used only the prescribed Alpha Systems sealants. BTW, the first question from CS rep asked was which brand of sealant have I been using.

The trailer is less than 3 years old and should be covered by the structural warranty I have contacted Grand Design customer service and received a case number. Photos and a video have been sent. GD wanted me to take it to a dealer but I asked if I could take it to an independent that specializes in repair and service and doesn't sell RVs and was given the OK. Have an appointment for Oct 10 to have the damage inspected and a report for GD. GD has handled my previous issues in exemplary fashion, one of those issues pretty significant. I hope that level of customer service still exists.

I have to say, I'm becoming a bit weary of having issues with this trailer. As an electrician and pretty fair mechanic, I can take care of most problems with an RV but this unit is wearing me out. This past trip I let out a sigh of contentment, thinking I'd finally gotten most of the bugs worked out. Well, except for that cricket that hopped into the front storage, finally chased him out after a couple of days.

My delamination looked like your first and fourth pictures and did not look like the center two. General RV showed me pictures of the two square pieces they cut out of the center above the slide which showed the sub material that was butted together which was spreading. No water intrusion. General RV assured me they have experience in this issue where they glassed in two solid pieces back in. It has not changed but then again I have not traveled that much. I wanted to get this done since its under warranty and it has been documented. Grand Design asked for photos and some specifics then covered the repair without issue.

 

[MidwestCamper]

View attachment 15339

Took this photo today.Looks like there's more going on than I first thought. There looks to be 3 or maybe four spots above the slide. Removed the bulb seals for inspection and 303 treatment. The bulge has pulled the seal track away from the sealant and the track is drooping a little. I can see behind the track and can get a finger back there, can feel the space between luan and the aluminum framing. There is no sign of water intrusion that I can see. The track is sealed along its length except where the major bulge is. I placed some Gorilla tape over the gap to keep water out. Fortunately the trailer hasn't seen rain in over a month.


I just told my wife about the situation. She reminded me of one day last week when we were in La Pine, OR when we both heard a "pop" from the dining slide area. She asked me if it was the slide settling at that time. I said nah, must've been a pine cone or something. I wonder if the glue let go at the most prominent site. I'm all over the trailer pre trip, always check the roof and seals. I've noticed the one spot before but it was just a visible joint, couldn't feel any raised area.

Thanks for the encouragement. We really love "camping" in this very comfortable and spacious trailer. My plan was to own it for 10 years, hope it works out!

Chief,
You may have something here. Friction from the slide pulling the luan away from the aluminum box channels? A jointed section could be the weakest area?

 

[Chiefblueman]

Here's the story-
I consulted with a respected independent RV repair service that's been in the business for 20+ years, had them do an inspection and report. I also consulted with an RV repair company that specializes in delamination repair. Both entities advised not to repair this by regluing and clamping.

When I mentioned possible wall replacement to GD, I ran into a wall. They would not consider it. The initial proposal was to take it to a dealer and have them fix it. I wasn't happy with that and went further up the chain. The outcome was that Grand Design will send their factory mobile repair tech to the dealership to train them on delam repair. Their method will be to hyper extend the slide, inject glue into the wall and clamp it. When I raised concerns about this I was told if it didn't work they wouldn't leave me hanging. We shall see.

Having a couple of experts advise not to do this has left me a bit skeptical. These are folks that have repaired thousands of RVs. However, GD has accepted this as a warranty claim and I'm grateful they will take care of this.

 

[MidwestCamper]

Here's the story-
I consulted with a respected independent RV repair service that's been in the business for 20+ years, had them do an inspection and report. I also consulted with an RV repair company that specializes in delamination repair. Both entities advised not to repair this by regluing and clamping.

When I mentioned possible wall replacement to GD, I ran into a wall. They would not consider it. The initial proposal was to take it to a dealer and have them fix it. I wasn't happy with that and went further up the chain. The outcome was that Grand Design will send their factory mobile repair tech to the dealership to train them on delam repair. Their method will be to hyper extend the slide, inject glue into the wall and clamp it. When I raised concerns about this I was told if it didn't work they wouldn't leave me hanging. We shall see.

Having a couple of experts advise not to do this has left me a bit skeptical. These are folks that have repaired thousands of RVs. However, GD has accepted this as a warranty claim and I'm grateful they will take care of this.

Chief,
For what its worth, my dealer mentioned this type of repair (if chosen based on situation) which is very strong and is successful when done correctly.

 

[Cate&Rob]

Hey Kim,

I think this is a reasonable plan.

As GDRV grows, they have to figure out how to repair things like this without bringing every rig back to their factory service center. We met their field service guys at the Indiana Rally and saw the service rigs that they have been provided with. These guys are the best of the best and GDRV has given them the tools to get the job done.

If, for some reason, your rig cannot be repaired to your satisfaction by the field service tech, I am sure that GDRV will still take care of you as they have promised.

Please keep us updated.

Rob

 

[Chiefblueman]

Hey Jim, thanks! I'm looking forward to getting this done. I'm sure it'll be fine. Kudos to Grand Design for covering this. To their credit, they never questioned whether this would be covered. Their willingness to fly a factory tech out to facilitate the repair is to be commended.

 

[Chiefblueman]

Hey Kim,

I think this is a reasonable plan.

As GDRV grows, they have to figure out how to repair things like this without bringing every rig back to their factory service center. We met their field service guys at the Indiana Rally and saw the service rigs that they have been provided with. These guys are the best of the best and GDRV has given them the tools to get the job done.

If, for some reason, your rig cannot be repaired to you satisfaction by the field service tech, I am sure that GDRV will still take care of you as they have promised.

Please keep us updated.

Rob

Thanks Rob! Appreciate your support. This is the same conclusion I came to. If this had been another manufacturer I'd probably be out of luck.

 

[Aridon]

Here's the story-
I consulted with a respected independent RV repair service that's been in the business for 20+ years, had them do an inspection and report. I also consulted with an RV repair company that specializes in delamination repair. Both entities advised not to repair this by regluing and clamping.

When I mentioned possible wall replacement to GD, I ran into a wall. They would not consider it. The initial proposal was to take it to a dealer and have them fix it. I wasn't happy with that and went further up the chain. The outcome was that Grand Design will send their factory mobile repair tech to the dealership to train them on delam repair. Their method will be to hyper extend the slide, inject glue into the wall and clamp it. When I raised concerns about this I was told if it didn't work they wouldn't leave me hanging. We shall see.

Having a couple of experts advise not to do this has left me a bit skeptical. These are folks that have repaired thousands of RVs. However, GD has accepted this as a warranty claim and I'm grateful they will take care of this.

Seems reasonable.

If they're confident in the repair they can extend the structural warranty 3 years in that area.