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Old 10-18-2020, 07:03 AM   #1
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Ramp floor fell off frame

Have a 2016 xlr thunderbolt 385. Ramp floor came away from the frame while in the deck position when my wife walked on it. Wondering if anyone has heard of this happening before and if we have any recourse on a 4 year old trailer? Ramp was just plywood and Styrofoam. Thanks
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Old 10-18-2020, 09:32 AM   #2
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Welcome to iRV2

Sorry your first post is about problems .

There appear to be wet spots in the gravel beside the chair , did water come out of the ramp after it came out of the frame ?
Anything in the manual about leaving the ramp open in the rain ?

If your model is still available , in a brand new unit , and the ramp/ deck, is built differently, then probably the manufacturer became aware of the issue and changed the design .
Then ; just maybe ; there could be some recourse.
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Old 10-18-2020, 09:33 AM   #3
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Get a lawyer.
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Old 10-18-2020, 10:13 AM   #4
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Originally Posted by 2buckeyes View Post
Have a 2016 xlr thunderbolt 385. Ramp floor came away from the frame while in the deck position when my wife walked on it. Wondering if anyone has heard of this happening before and if we have any recourse on a 4 year old trailer? Ramp was just plywood and Styrofoam. Thanks
Yes, we have seen this issue on some toy haulers. Who is the manufacturer of the ramp doors? I guess it is a Lippert door. I am not saying this because of what happened but because of the construction used. It is subflooring and Styrofoam. They are 3 manufacturers of the ramps, that I know of, Lippert, Challenger and Morryde.
As far as leaving these things down in the rain, you should not do this. Some people I know who have a Lippert ramp have called and asked Lippert about leaving it out in the rain and Lippert replied was to store it during rainy times.
Did you check the caulking on the ramp door to make sure it was still good and sealed?
As far as any recourse, maybe Forest River will help in replacing it, probably not. You could try talking to the maker of the ramp door and see if they will help out. Some I know has had Lippert offer a replacement ramp but they had to pay for shipping to get it. But not a good chance.
Heartland switched from Lippert ramps to Challenger ramps, because of this issue, sometime in 2017. I am not sure what Forest River uses as a supplier.

If not you may find a replacement ramp at a RV surplus place, such as
Bontrager's (https://bontragers.com/)
or try Rainbow Variety (https://rainbowvarietystore.com/).
I have seen replacement ramps at both of these places, we were in Goshen in June/July 2020 and they had some sitting there. We will be back in Goshen on October 26th until the end of the month for modifications to our rig, so send me a PM if you want.

Good luck.
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Old 10-27-2020, 05:46 PM   #5
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just have to start calling around but damn that is not good!!
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Old 10-27-2020, 05:57 PM   #6
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Originally Posted by Pete1985 View Post
Get a lawyer.
For what reason? Owners need to do maintenance on their rigs, even fairly new ones.
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Old 10-27-2020, 09:59 PM   #7
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So why would you even want it fixed? If you had used that toyhauler how it was intended, there's likely to be a vehicle shaped hole in that ramp.... Can you imagine rolling a thousand pound off road vehicle or a harley up on that?

I'd remove the existing filler and:

Fabricate a overlapping frame to be welded to the outside of the existing frame

Fill the frame with a more durable design - I'd start with the original outside sheet, because it already has the metal or fiberglas layer to look good. Then you need to figure out what combination of plywood, OSB, and readily available foam needed to make the new ramp roughly the same thickness as the old, but just inside the skin you should have a layer of 1/2 to 3/4 and the same on top.

Glue it all together with construction adhesive and drill/countersink holes around the overlapping frame for a couple dozen large screws.

Easy peasy weekend job. You may even be able to leave it out in the rain afterwards....
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Old 11-15-2020, 05:35 AM   #8
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I'm amazed at the cheap build quality of TH and RV's in general. That ramp was built to support a child toy not an adult toy.
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Old 11-17-2020, 04:55 AM   #9
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I just replaced the ramp door on my 2016 stryker. 3600.00 bucks.
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floor, frame

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