This summer has been busy, in a way…..

Well, I’ve not posted for a while. It certainly isn’t because nothing has been going on – quite the contrary. There will be several different posts, so this is just an over view.

Summer is supposed to be a time where one only has to choose between mowing the lawn and taking a trip somewhere in your trailer.  Not so much for us this year.

Going back, waaaay back, before the spring trip. Last November I spent a day helping one of my sons remodel his basement. Much of the day I was working overhead on wiring. When I quit, my shoulders were both quite sore. I’d been through this before – after a few days, they’d get better. Well, they didn’t. Christmas came and went. Then a doctor’s visit and some shots, some therapy – and nothing really helped. Finally, an MRI on the worst shoulder confirmed my fears, a torn rotator socket. Three tendons needed repair and a bone spur cut off. Another month of waiting for surgery and 6 weeks waiting for PT to begin because of the extent of the damage, then a couple of months of physical therapy. All this time, I’m trying to not abuse my other arm – but it keeps getting worse. So another MRI and it confirms significant damage as well. Another month of waiting, and another surgery and another 4 weeks minimum to wait for PT to start and 2-3 months of PT and another 2-3 months of exercise on my own and, in theory, I’ll be back to my old self.

In other words, about 15 months where I’ve not been able to do the things I normally do. I’ve certainly managed to squeeze in some work with help, but not like I would normally have done. There will be blog posts on the two trips, the two construction projects and two hitch installs. Oh, and two kids, 4 grand kids lived with us most of the summer.

So, it all begins over again. Our 2017 Flagstaff trailer is up for sale. Our hope is to find someone that would like a trailer that has not only been upgraded, but has had many of the design and construction faults corrected. Our plan is to move up to a Class C which is capable of towing our pickup truck . As such we already have a list of upgrades that we would need to do to most any Class C we find. We are currently looking at several models.

Things we would do again, eventually:

  1. See Level II tank monitors.
  2. TPMS – though I’d like to consider installing internal TPMS. I like the Tire Minder smart system we have on the trailer EXCEPT, I have to pull them off to manually check or change tire pressure. TPMS are nice to have to monitor for a leaking tire but aren’t accurate to the pound. There are “T” adapters that can be installed, but not if we have rubber tire stems. Most Class C’s have at least some rubber stems – so I’d have to pull the tires to add metal stems – why not just add TPMS internally? I’m still researching this one.
  3. Batteries – we currently run two deep cycle 12V batteries in parallel. As I look at Cs, I’m looking at the battery boxes to see if I can put a pair of decent quality golf cart 6v batteries.
  4. Solar – the C’s we are looking at have generators, but I’d still like to have some solar.
  5. We currently operate off a portable hotspot and our phones. There is no decision yet, but I’m looking at various wi-fi and cellular aware router/repeater configurations.
  6. If not already installed – porcelain toilet. At least something that doesn’t squeak and rock when you sit on it.
  7. Temperature monitoring system (fridge, inside, outside).
  8. Central Vac
  9. If not already installed – digital thermostat.

I’m sure there are other little things.   We want to find one with better shades. Some come standard with dual roller shades. And if it comes with huge valences like our trailer did, they will have to be removed and cut down. Some we are looking at use a different design for valences – wood on top and cloth hanging down to cover the shades.

At this point, we see the trailer as a huge learning experience. We kind of worked backwards. We bought a truck without really having a notion we’d end up towing an RV trailer. We did get the towing package, but it was a 2.7liter ecoboost, with a tiny gas tank.   Then later, we went out and picked just about the largest trailer we could tow – but later we discovered we were probably somewhat overloaded when we got around to weighing the combined rig.

We started with what we thought was an Equalizer hitch – but ended up with a Fastway E2 hitch – which is the cheaper foreign made version – which again was was probably overloaded by this trailer. Recently we installed a ProPride P3 hitch on this trailer and my daughters – and there is no comparison. Sway is essentially eliminated, though installation was considerably more difficult than expected. It was compounded by the cheap method Flagstaff (Forest River) chooses to install the safety chains.

I will again, be crawling through our new Class C looking for the kind of crap that gets built in during constructions. Improperly connected wires has been a consistent theme on BOTH our trailers in the family.   Not just jack lights but crucial items like Brake Break away switches, trailer brakes, main battery cables and tail lights.

Finally, I’m seeing that many new RV’s have multiplexed control systems in them. While the RVIA (yes those bastards) are developing a standard called RV-C, what is being installed today is a mix of manufacturer provided products. Typically Lippert. Their specification is simpler and seems to allow for end user customization – which is going to be important for me. And since there are never any wiring diagrams available to owners, I’ll have to be making my own because if I have trouble with a multiplexed control system I don’t want to be diagnosing a problem with no idea where the wires run. Some 2018’s still use traditional wiring – which will be fine with me.

So a number of posts are coming soon!

The Factory Tour.

I’m not going to list the specific factory or any personnel, because I believe it won’t matter which Forest River factory your trailer is assembled in, the problems with trailers are systemic and designed in.

We wanted to see how the trailers were built.  I had seen enough of trailer construction crawling through them at shows that I knew it would be a lot like watching sausage being made  – and it was.  We parked at the front of a very large complex of buildings and went in and met our guide – who ferried us to the back of the factory in a car.  On the way we passed a sizeable horse barn with a bunch of buggies parked outside, thus we knew much of the labor inside would be Amish.  I need to say, they were very personable, greeted us as we walked through the factory. They were all working hard, industriously.  No standing around.  I don’t blame them for the shoddy construction – and I know without a doubt, that if they were building a trailer at home, they would not use any of these materials or construciton methods.

Fresh Water Tank on bare trailer
Fresh Water Tank on bare trailer
Fron to back on bare trailer
Front to back on bare trailer
Black and Grey tanks on bare trailer
Black and Grey tanks on bare trailer

As we walk in, we see bare trailer frames – wheels, axles and not much else.  They get flipped on their side and various components, wiring etc. are installed from the bottom.  Then back on wheels, to add the plywood deck.  Then the vinyl flooring covers the entire trailer.  Back upright, the trailers are rolled onto dollies that allow them to be rolled sideways down the assembly line.

The trailers are then built from the inside out.  Major interior wall sections, cabinets, the shower, etc are installed on the bare platform.  Wires are pulled up through the floor and cabinets as the construction continues.

There is another factory building across the parking lot were the sides, ends and roof are constructed separately.  They have a welded aluminum frame, filled with styrofoam and a thin layer of fiberglass on the outside and a VERY thin plywood covered with cheap vinyl wall-paper on the inside.  The side walls come over “just in time” and are added to the trailer.  Then the end caps, just in time as well, and finally, the roof is laid on.  Once the trailer is boxed in, there is still a great deal of work to be done inside.  Cabinets to be hung, electrical panels and wires connected.  Plumbing, vents, ducts.  Windows, valences, shades and more.   We were invited to walk through a partially completed trailer – and there were dozens of little pieces of tape marking spots that needed some work.  Dozens.  They were big on the inspections – but more on that later.  As the trailers neared the end of the line, all the pieces of tape slowly dissappeared.  At the end, they sprayed soapy water on the outside and put a fan in the door to check for leaks.  Then the hitch was picked up by a tractor and rolled outside – unless there are still tape tags, in which case the trailer is moved to a repair slot where it gets additional work.

So, in a way – not much to see that wasn’t unexpected.  So here are some numbers.  They build 18 to 25 trailers a day.  The factory floor holds maybe, a dozen trailers – so the first trailer has to be done and out the door in less than half the shift.  Even if they ran 12 hour shifts that means a trailer is done in less than 6 hours – my estimate is closer to 4.  Think about that.  From start to end – 4 hours.  That isn’t even enough time for many of the glues and caulks to harden properly.  Every worker is under pressure to work quickly – to not spend extra time on getting something right.  EVERY part of the design is specified in a way that uses the cheapest materials that allow the fastest construction methods.  More glue, more staples, sloppy cuts, power fasteners all in the name of quick construction.

Near the end of the tour, we walked passed a windows PC which caught my attention.  The tour guide took my interest and pointed out that the screen had all of today’s build trailers listed.  He even pointed out which trailer would get the final inspection in a nearby building.  See, ONE trailer from each days run would be taken to another building and inspected.  He bragged that they had the best record of any Forest River factory – even that last year, they had One Perfect Trailer.  Wow, ONE WHOLE PERFECT TRAILER.  In case you missed it above, which trailer would be inspected was listed on a PC screen right next to the assembly line for all to see.  And remember, this inspection only checks to see that the trailer is built to design specs – it is no measure whether the trailer is actually built to any reasonable expectation of quality OR safety.

We bid our tour guy good bye and left in a state of shock – more or less.

 

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