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Old 09-21-2022, 02:15 PM   #1
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Sandwich floor soft spots-repair suggestions

2017 Kodiak 201QB. Has a soft spot in sandwich foam subfloor at pivot point where you turn to walk down. Pretty sure it is due to too large a span between joists which we assume are aluminum.

Seen repairs involving export injections, adding wood joists and bracing, 5/8 plywood replacements and adding aluminum joists. Seems to be common problem in ultralights made in mid 2014-2017.

Suggestions for most cost effective repairs? Any repairs we can do ourselves? Plan to recover sub floor with vinyl tongue and groove planks.

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Old 09-21-2022, 06:07 PM   #2
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I actually know what you are talking about. I looked at a used Zodiac trailer that every step I took was soft. Not just one spot. The whole floor was soft. I thought I would need to rip the old floor out an put in a new heavier floor.

I did not buy the trailer but will say every repair I have made to my trailers I always used heavier wood.
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Old 09-21-2022, 06:32 PM   #3
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I have never done a job like this but I watched a video on this subject by AZ Expert…might be the same video you watched. I think he fixed the whole floor of the unit from the inside and from the top. Big job! I am not familiar with Kodiak construction, but I watched part of the YouTube video “Dutchmen Kodiak factory tour” to get an idea for what the frame looks like. I see that you would have to remove a portion of the coroplast bottom to expose the frame. The joists look to be 4’ to 5’ apart. How large of an area is your soft floor? Below is a screen shot of your floor plan and a shot from the factory tour showing a Kodiak frame. I am wondering if it is possible to cut out a rectangle of the soft floor - add framing and plywood under the cutout - and then infill the hole with various plywood thicknesses back to floor level of the sandwich panel?…just thinking out loud here. AZ Expert welded in the additional framing, but I am not a welder so I would have to figure an alternate method of attachment.
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Old 09-22-2022, 06:48 PM   #4
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i have the same problem, its not bad just annoying. my idea for a fix is to use a thick wood flooring. i see some at the builds supply that are near 3/8+ thick solid wood. i believe some snap together or can be glued. this should stiffen it up considerably. i would like a new floor anyway. I'm only talking a strip aprox. 4' wide 12' long. less width in some places. i don't see any place that the extra height would be a problem. i may be going to the big city this weekend and check some out.
i also welded a section of angle under the floor that helped some. the joists are defiantly to far apart mine i believe are about 36". way to much to support any amount of weight when walking on it. me taking a step puts 175# all in one spot, sure its going to be a little spongy. you've got me thinking about adding more joist and the plank floor. i defiantly don't want to tear into the composite floor
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Old 11-22-2022, 10:46 PM   #5
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If it gets worse with time, it is almost certainly wood rot due to a leak. Mine was (Luckily) due to a leaky hot water line. First fix the leak. Then proceed. Good luck to you!
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Old 11-23-2022, 10:38 AM   #6
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as mentioned in a post above we have a similar problem. its not water damage, its the composite floor and lack of proper support. i just installed a pull-down step system with air support. it comes with reinforcements for the floor BUT it's not enough for the composite floor. too much leverage at the door sill area when pulling the stairs down against the air cyl.. I'm a welder so i may weld in a reinforcement under the floor area, but most likely i will do something on top. its not really the floor thats the problem, its the foam thats in-between thats not strong enough to support the leverage of the steps being pulled down.
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Old 11-23-2022, 11:54 AM   #7
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The used Skyline Koala was soft everywhere. Not just one area. I looked at new Skyline Koala trailers and really liked it. Glad I did not buy one. They do this to keep the unit very light. This trailer also had composite cabinet doors.
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Old 11-23-2022, 12:25 PM   #8
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Light and strong seldom go together unless you add lots of $$$'s!

If I was the OP, I'd probably cover the entire visible floor with 5/8" plywood then new linoleum.

2 cents,
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air, floor, repair

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