Cracked Frame Support

[X-OEM]

The frame support for my full wall slide is cracked. It makes the use of the slide impossible.

Anybody have an issue like this in the past. I have been told that the only facility that can repair this is the factory.

First picture is a wide angle of the area. Second picture is a closer view.





BTW - It is the the slide closest to the back of the unit

[outlawten5]

I would think any competent welding shop could repair this. I know I could.

[Dav L]

Y, the default answer from non DIY'rs is bring it to the factory. In actuality, any decent fabricator can repair that if they are inclined.

If I am seeing the crack (vertical down the rectangular tube?), I would jack the tube end up to close the crack, wire brush clean, weld the crack shut, grind flat, put a plate ontop and weld that too. If the plate doesn't get in the way of mechanism. Add a strap across the top and tack that down a foot to really strengthen it from downforce.

I predict a 3 hour job or about $400. Beats driving X miles to the OEM.

[X-OEM]

Thanks for the replies. I suspected that as well, but have always seen this forum as a wealth of information and sound advice. I am pretty sure there is room to weld a plate over the damaged area.

Thanks again everybody!!!

[Firedog3722]

I found the same thing on my 2011 Essex. I had taken the coach to NIRV Atlanta to have the slide adjusted and a few other items. After a couple of attempts and the changes not effecting what was happening they did some searching and found the crack. It ran from top to within a half inch of the bottom, but you could the crack extension (looking like a hair) went to the bottom of the beam. Cost to repair (not fix) was a little over 5K and I now I can use the coach. Better than going to the scrap yard.

What has been suggested (jack to close the crack, wire brush, and weld) sounds good but you have to imagine what really happened. One would think that the metal beam just cracked, but in reality it bends a little before the crack happens. If you just push it up and weld you have not taken the "bend" part into consideration so the beam end is really still lower than it should be, needs to be higher.

I say this because I believe that is what was done to my coach (above). I just had the slide adjusted again because it was touching the opening again, locally, and I don't have any adjustment left (The wall adjustment is as high as it will go) and I'm only1/16th to an 1/8th inch above the FWS opening at the position for the rear arm.

I can see repair from the outside, it is a round piece of metal that was welded over the crack, I don't know if they welded the crack first. Funny thing was when it came back from being repaired my inverter/charger was not working correctly and I sent it to the Magnum mothership for evaluation and two boards needed to be replaced for $800 with a 90 day warranty. Bought a new one for 1500 with a few years of warranty.

I'm thinking of taking the coach to the factory and getting some other work done it, maybe a new beam if it can be done?

I was told my repair shop talked to the factory about this. I was also told the factory had not seen this before, so now there are two.

[X-OEM]

Actually there are three known cases of this. Another member reached out to me yesterday with exactly the same issue and was kind enough to explain (with pictures) what he did to repair his crack.

Thanks for the very thoughtful feedback. I will take this into account.

[Jabber Jaw]

I would recommend taking it to Newmar for a couple of reasons:

1) Newmar will probably do the repair under "warranty"!

2)Newmar "Engineering" needs to see it; evaluate it for the future (if not already); to protect other Newmar Coach owners!

3)They need to figure out exactly what happened, & why!

[Dav L]

Originally Posted by Jabber Jaw

I would recommend taking it to Newmar for a couple of reasons:

1) Newmar will probably do the repair under "warranty"!

2)Newmar "Engineering" needs to see it; evaluate it for the future (if not already); to protect other Newmar Coach owners!

3)They need to figure out exactly what happened, & why!

And all of that can happen with good pictures and a check in the mail if Newmar is so inclined.
Sure, taking it to Newmar is best (for them), but factor in what a PITA it is to schedule, drive, camp, deal with the several days it will take them. Who reimburses that? Maybe if one doesn't have anything else going on then it's all part of an adventure.

$4000 to make that repair? yikes...sounds like a dealer story. Hard to throw stones when one doesn't have enough info (one picture), but that sounds like a home run (typical). That's 30 hours of work...doesn't like like there are parts / materials involved...unless the paint had to be redone due to damage from misalignment.

Coincidental of the Magnum getting fried right after welding? Hmm, sounds like the welder didn't remove the power / battery connections and ensure a good clean, close ground for the welder...

The above stories are exactly why I DIY such repairs. No one to blame but myself...

[X-OEM]

OP here. My first call was to Newmar if for no other reason to get some information about the crack - assuming they had some. Also. even though the frame is not covered under original warranty, thought they might kick in some part of the cost.

They were not the least bit interested in helping with the cost of repair, and even though the coach is barely useable (I can only put the slide out about a 12 inches) , would not schedule something until November.

Yeah, I may have gotten a grumpy tech rep on the phone, and I could have pushed harder, but the drive from the RGV to their factory didn't appeal to me either, no matter what the time of year.

Making other plans