MConnelly
12-24-2012, 04:40 AM
I love to tinker, repair, improve upon etc. so the 2009 Fuzion 403 I bought in July of 2011 was the perfect rig to buy. So much potential. So many hours of tinkering enjoyment.
This was my first rig. I thought I did my homework...
The rig had no miles on it or any use before I bought it.
All the tags were still on the appliances and no warranty cards had been filled out. It was for all intents and purposes, new.
The opportunities I have had to "tinker" on the rig were all courtesy of the fine craftsmen at Keystone/FUZION
This is a list of "tinkers" my rig has needed to date.
Rear side marker lights..bare wires rubbed on frame and shorted out. Numerous grommets later all wires running thru the frames were protected.
Fuel station...pump wired backwards overheated , burned out. Replaced pump , wired correctly. (keystone supplied the pump)
Fuel Gauge...wired backwards, read empty all the time. Needed new gauge wired properly.
The doors on the main switch control panel were 1/4" too big so the doors would not close. Cut each cabinet style down 1/8" ..rehung doors.
Master bedroom window leaked. Removed , re sealed, re installed.
Main cargo side door would not close properly. It was already bent when installed. New door installed.
Main DC lights and reading lights were wired together in the salon, even though there were two separate switches. Re wired switches.
All the decals curled up. Removed them. Then re-painted the entire rig.
Master bedroom slide floor rotted out. No sealant from factory. Replaced floor, properly sealed.
Entire master bed frame needed to be re built as no screws were installed properly.
Bed Frame was not attached to Slide. Attached using proper screws and anchors.
Pinched AC wire between steel slide mechanism members. Re routed wire.
Heater motor rusted ...heater mount flange was never caulked allowing water to get to motor. New motor, sealed housing mount.
The tires on my 2009 rig were made in 2007. Junk to begin with . One blew out. All were dry rotted. All seven have been replaced.
Stripped screws in toilet flush mechanism..toilet would not flush properly. Heli Coils and new valve body.
OEM water pump was pitiful. Upgraded to higher flow pump.
The rear cargo ramp core broke along the hinge line. No sealant in the lower U channel allowed water to separate the core materials. Cut loose bad materials, sealed the channel and substantially increased the size of the hinge contact area with the ramp. Now, straight, even, and solid as a rock.
Trim pieces not properly installed. Removed trim pieces and anchoring brads. Then glued the trim in place. Touched up all small brad holes with matching filler.
Several AC plugs needed to be taken out of their boxes and the connection screws screwed in. I cannot say tightened because that would imply they had been screwed in at some time.
Generator exhaust routed to exhaust under awning and master bedroom main window from factory. Re routed exhaust to other side of rig and installed a venturi vent stack.
Frustrated? At times. However I now know the rig so well I am very comfortable with it's abilities to service my needs. I stay cool in the heat, warm in the cold, dry in the rain. It tows great. Looks great, with it's new paint. Everything works properly.
Had all this work been done at a repair facility the rig would have been history long ago. As I have the abilities and facilities to do my own work the costs for the work have not been substantial. I am recently retired so I have the time.
Seven new tires and the painting materials, were the most expensive costs , by far, for all the work I have done.
Now that the rig is all working properly and is "sound" I am going to do some interior remodeling to incorporate better living room space in the garage.
The rig has "grown on me". It is truly mine. Repairs seem to be over and upgrades are simply enjoyable.
Recently my wife and I spent almost three months on the road with our 403.
She jokes our main requirement for where to stay is it has to have a Lowes or Tractor Supply near by!
Hope you have enjoyed my journey.
This was my first rig. I thought I did my homework...
The rig had no miles on it or any use before I bought it.
All the tags were still on the appliances and no warranty cards had been filled out. It was for all intents and purposes, new.
The opportunities I have had to "tinker" on the rig were all courtesy of the fine craftsmen at Keystone/FUZION
This is a list of "tinkers" my rig has needed to date.
Rear side marker lights..bare wires rubbed on frame and shorted out. Numerous grommets later all wires running thru the frames were protected.
Fuel station...pump wired backwards overheated , burned out. Replaced pump , wired correctly. (keystone supplied the pump)
Fuel Gauge...wired backwards, read empty all the time. Needed new gauge wired properly.
The doors on the main switch control panel were 1/4" too big so the doors would not close. Cut each cabinet style down 1/8" ..rehung doors.
Master bedroom window leaked. Removed , re sealed, re installed.
Main cargo side door would not close properly. It was already bent when installed. New door installed.
Main DC lights and reading lights were wired together in the salon, even though there were two separate switches. Re wired switches.
All the decals curled up. Removed them. Then re-painted the entire rig.
Master bedroom slide floor rotted out. No sealant from factory. Replaced floor, properly sealed.
Entire master bed frame needed to be re built as no screws were installed properly.
Bed Frame was not attached to Slide. Attached using proper screws and anchors.
Pinched AC wire between steel slide mechanism members. Re routed wire.
Heater motor rusted ...heater mount flange was never caulked allowing water to get to motor. New motor, sealed housing mount.
The tires on my 2009 rig were made in 2007. Junk to begin with . One blew out. All were dry rotted. All seven have been replaced.
Stripped screws in toilet flush mechanism..toilet would not flush properly. Heli Coils and new valve body.
OEM water pump was pitiful. Upgraded to higher flow pump.
The rear cargo ramp core broke along the hinge line. No sealant in the lower U channel allowed water to separate the core materials. Cut loose bad materials, sealed the channel and substantially increased the size of the hinge contact area with the ramp. Now, straight, even, and solid as a rock.
Trim pieces not properly installed. Removed trim pieces and anchoring brads. Then glued the trim in place. Touched up all small brad holes with matching filler.
Several AC plugs needed to be taken out of their boxes and the connection screws screwed in. I cannot say tightened because that would imply they had been screwed in at some time.
Generator exhaust routed to exhaust under awning and master bedroom main window from factory. Re routed exhaust to other side of rig and installed a venturi vent stack.
Frustrated? At times. However I now know the rig so well I am very comfortable with it's abilities to service my needs. I stay cool in the heat, warm in the cold, dry in the rain. It tows great. Looks great, with it's new paint. Everything works properly.
Had all this work been done at a repair facility the rig would have been history long ago. As I have the abilities and facilities to do my own work the costs for the work have not been substantial. I am recently retired so I have the time.
Seven new tires and the painting materials, were the most expensive costs , by far, for all the work I have done.
Now that the rig is all working properly and is "sound" I am going to do some interior remodeling to incorporate better living room space in the garage.
The rig has "grown on me". It is truly mine. Repairs seem to be over and upgrades are simply enjoyable.
Recently my wife and I spent almost three months on the road with our 403.
She jokes our main requirement for where to stay is it has to have a Lowes or Tractor Supply near by!
Hope you have enjoyed my journey.