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Old 12-15-2020, 03:32 PM   #1
PaulForinash88
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Thumbs down Delamination on 2017 Cougar

Have a side panel that has delamination with no water damage or any underlying cause. Dealer said its a manufacturing defect caused by the fridge not being vented correctly. We have warranty forever and the extended but are being told neither help in a manufacturer defect and to submit to insurance.. insurance guy says same thing..new camper with no underlying cause is a design flaw... not too sure where else to turn.
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Old 12-15-2020, 07:42 PM   #2
JRTJH
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If Keystone, the aftermarket extended maintenance plan (never call it a warranty) and your insurance won't address it and your dealership is reluctant to attempt repair (or you're reluctant to turn them loose on your trailer), you might consider a marine fiberglass repair business. Look around your area and talk to some boat dealerships to recommend a fiberglass repairman.

It's a simple matter to drill holes from the inside and to inject adhesive, then press the outside to help it adhere. The trick is knowing how to drill the holes, inject the adhesive and push "enough to get good contact without damaging the surface of the FILON".....

It's not going to be cheap, but there are ways to fix that without drilling a bunch of holes in the outside or removing the FILON sheeting.....

The priority, IMHO, would be to address the "manufacturing defect in refrigerator venting"... I'd get that fixed before repairing the FILON issues.

ADDED: Looking at your photos, are you sure that you're experiencing "delamination"???? The Cougar line uses only a single layer of 1/8" luan as a backer for the FILON. Where the sheets of luan butt against each other, there is often a "ripple" which is easily seen on the surface of the FILON. It looks like there may be a "luan butt joint" along the vertical aluminum stringer that forms the edge of the refrigerator vents. I've got a couple of places on both sides of my Cougar that look very similar to your trailer. On mine, it's not "delamination" but rather "luan butt joint ripples".... I'd make sure exactly what you're facing before "fixing the wrong issue"....
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Old 12-15-2020, 07:53 PM   #3
PaulForinash88
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The dealer we got it from said it was delam. A rep from keystone and the dealer inspected it and agreed but wouldn't say why or accept responsibility...just never seen it without prior damage before..spontaneous delam.
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Old 12-15-2020, 08:22 PM   #4
JRTJH
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Walk around several Cougars on dealership lots and look for "vertical ripples". I'd suspect you'll find several that have similar issues. I'm no expert, but I've seen it on trailers ever since FILON became a "sidewall option". It is, I suppose, delamination of sorts. It's typically "delamination (really separation) of the luan" from the underlying aluminum framework, not "delamination of the FILON" from the luan. It typically occurs where the luan butt joints are located and is caused by either the plys in the luan separating or from the luan separating from the underlying aluminum. When that happens, the FILON that is glued to the luan as well as the underlying luan will "ripple".

The issue isn't as prevalent on "higher priced Keystone products" as they use a double luan backing system with alternating butt joints, so in essence, there's 1/4" of luan, not 1/8" and the butt joints are staggered. So on those trailers, the only "luan caused ripples" are from the ply separation on the luan panels, and that usually doesn't occur over a large enough area to be visible on the surface (unless there's water intrusion involved)...

I don't suppose you'll find that Keystone would agree to repair it. The 3 year structural warranty would probably cover the issue, but that warranty program didn't start until September of 2018 (I think) and only applies to units built (not sold) after that date.
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Old 07-13-2021, 04:51 PM   #5
wht1955
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Bill

My 2017 28sgs has the same issue over. 7k for repair at dealer .
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Old 07-13-2021, 05:04 PM   #6
wht1955
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I have attached photo, seems odd yours delaminates in the same place. I believe something else is going on with the delamination issue.
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