Broken ORV frame

[Keodie]

A little story for folks...
22 24RLST and maybe 20k on it.
Broken I beams at the cross members. Breaks are being pushed outward at the cross members, and the I beams excessively moving laterally. This is from the cross members not having sufficient or complete welding and bracing. This was confirmed by a highly qualified, licensed, fabricator.

ORV says they will not participate in this repair, sorry, because I was 45 days out of chassis warranty when reported. They then tried to say that I had overloaded the trailer and that I not supported the axle while doing brakes and bearings. Pics sent to ORV show a bottle jack and a jack stand clearly supporting the axle. I also weigh my axles at state dot scales, almost every trip, I pass them, and sent ORV my absolute heaviest weights and was still under by 900#. Doesn't matter, 45 days past chassis warranty.

So, you all that have some of the heavier models, may want to really check your frames. They are built on the same beams.

No odd wear or damage to suspension or tires.
I will show the exact same pics sent to the factory. I will show a couple more pics showing the cross member attachment in another post

[Keodie]

More pics

2 are from the inside looking at the cross member at the I beams.
2 are close ups of the cracks

[Old-Biscuit]

Axle overload would have taken the upward bend out of them

Who makes the frames for ORV............Lippert?
*Lippert frames had same issues for years

[fda fa]

Can anyone explain how "I had overloaded the trailer and that I not supported the axle while doing brakes and bearings." could cause and I-Beam crack?

IF RV was made to ORV specifications (assuming they are sufficient and not ideal), could there have been some very heavy load at rear of RV, including generator, e-bikes, or rack mounted to bumper area?

I will be watching my 21RBS I-beams.

@keodie How did you realize that there was a problem? If you saw the cracks and then looked into the problem, you deserve a lot of credit for being observant.

[Keodie]

Exactly!!
I have worked on rvs for over 30 years....not seen one like this before. We even used to do some flips /lifts on old school Terry's with no problems with the frames

[Keodie]

Never had anything more than 2 spares on the bumper and 2 mountain bikes on the back.
Found it while upgrading the axle brakes and bearings....was staring me in the face. I would have never seen it otherwise as it is behind the tire

[rarebear.nm]

Originally Posted by Old-Biscuit

Axle overload would have taken the upward bend out of them

Who makes the frames for ORV............Lippert?
*Lippert frames had same issues for years

ORV makes their own frames. The main lengthwise beams are I-beams.

[Keodie]

Yes. We all know they make their own frames, including cutting the I beams to lengths, as well as all other pieces.They ,however do not, govern the metal composition for what they use.
The lack of good weld and bracing, are just a couple issues that can make for a poor frame.
Pretty sure the lippert frame reference was a funny!

[fda fa]

Are there other cracks in this area or other areas of the I-beam, which could be caused by defective material? See third image, rust colored vertical line in upper left.

As Old-Biscuit said excessive loads might bend (straighten) the axle or I will add flatten the springs.

[Keodie]

Micro cracks at the front of the trailer...just mostly at the rear section

[Keodie]

The rust colored vertical lines are where the internal cross members are pushing outward with lateral forces.... lack of proper bracing and welding.

[BeatCJ]

Man, those are some ugly ropey looking welds. Looks like they were using it like a hot glue gun, not any thoughts of fusion or proper technique.

I suspect poor fitment of the cross members caused some oil canning of the web. It's an interesting failure pattern.

[Czechsix]

I would lay money on the beams being sourced from India.

Doesn't really matter at this point, but I think an competent welder/fabricator could easily do fish plates and reinforcements, and in the end you'll be ahead of the game.

I know I'm looking at doing some welding on our 250RKS, we have rough roads and the suspension setup is simply too light.

[Keodie]

Yes to all of you. Common sense tells you that it is lateral frame flex, multiplied by improper welding at the very least. Happening at all metal cross members, that are not fully welded. Well within the first year, it was documented at the factory, that most of the wall mount nuts underneath, were not tight, most weren't even bottomed out. I asked the factory what their torque specs for those nuts were, they told me to just tighten them. I am also on my 3rd entry door due to fitment issues that has caused that door to be absolutely stuck from the inside, unless you put a shoulder into it, while on a flat concrete pad. Also documented at the factory. Frame issues.

The most surprising thing is the stance that the factory superiors are taking. Trying to blame me for doing something wrong, that if I'd have done, would have caused way more damage. This failure has been happening since day 1. My heaviest axle weights were ...rear 4,300. and front 4,200...1500 under gvwr, 5,200 axles. This did not happen over 1 event either, which I tried to point out.

The only thing that I have asked from them is re imbersment for the repair itself......"sorry". I didn't want anything for my labor , dropping the corplast, and all required work required for proper repairs, and replacing/repairing and getting back on the road....again "sorry". 45 days past warranty. Everything that was underneath the corplast, touching the bubble wrap, has rusted.

I will definitely post more pics after I get the whole corplast down, and show you what I find. I can already see that the main freshwater tank support is completely rusted.



Btw....a hot glue gun can do a much better job than what's on the cross members

I beams say. Sti usa on them

I had another mobile, certified welder, come and look at it as well, lack of support to the really poor cross member welds, and then the very sub par welds.
More than capable and competent to do this myself, just needed professional support.... Gonna have everything checked by a certified, insured shop. Just a CYA.