Torn frame rail on Cougar 28RBS

[340_Formula_S]

As I was putting the front cover on the front of my Cougar 28RBS, I noticed that it wasn't lining up properly. The first question on my mind was why? I got down on the ground and went under for a closer look. What I found utterly shocked me, my frame rail was all but torn in two. I managed to find a truck repair shop near by and have it repaired well enough to get me home (500 miles away). To Keystone's credit, they told me to get it to a dealer to determine if it was a defect. I do a good bit of business at home with a great machine shop and decided to just have it repaired myself. I just didn't feel like having my trailer sit out all winter and it be gone, for most likely three months, for a repair that I can have done in a day. The lesson I wish to pass on here is simple, if something doesn't seem exactly right, it probably isn't. Do not second guess that little voice in your head that keeps asking why? For me, this was an almost certain disaster that was getting ready to unfold. I want to thank that little voice. Just a story I wanted to share with the rest of you here on the forum.

[therink]

What year is your trailer? Can you share photos? Do you have an idea what may have caused it? This may help others in what to look for?
I don't blame you for fixing it yourself. There is no price tag to put on the anguish you may have faced waiting for your dealer and Keystone to fix it.

[340_Formula_S]

My trailer is a 2013 model. I have no earthly idea what could rip the frame rail. However, the 28RBS has a hefty tongue weight. It is obviously a weak point in the design. The tongue did not kink or bend, it ripped the rail back behind where tongue meets the rail by several inches. I am going to plate both the inside and the outside of the rail and on both the left and right side with about an 18" plate x about a 1/2" thick.

[Ken / Claudia]

Help us out a little. After reading this and being real interested, I really do not know what your saying. Torn or ripped is hard to picture. Is the frame cracked, did it crack a weld? If it cracked/split is it up/down or front/back.

[340_Formula_S]

Not a cracked weld, it split the actual rail, from the bottom straight up to the top. There was nothing but the top of the "i" beam left holding, keeping an entire separation from occurring.

[Wing-in-it]

i would still report the damage......wasn't there a recall on some frames a year or so ago?

[JRTJH]

Originally Posted by Wing-in-it

i would still report the damage......wasn't there a recall on some frames a year or so ago?

I checked the Keystone recalls/notifications listing on the factory website and couldn't find any "frame related recalls" on any brand that had to do with cracked/torn frame members.

Certain year Cougars from 2007 to present have been involved with axle, bearing, spring hanger, and coupler issues, but not specifically frame related issues.

There were a couple of "heavy fifth wheel" owners who reported issues with interior closet panels vibrating loose during travel. It seems that the "upper deck" was somehow involved in that damage. There was some movement (up and down) of several inches between the "hitched" and "unhitched" measurement. Beefing up the frame was apparently the answer, but there was never a "formal recall" done on any of those issues as best I can find.

About 2 years ago, one member did report an "A Frame" movement issue. He reported that Keystone repaired his RV, but there have been no recent reports from him on whether the issue was resolved. That's the only travel trailer "Frame failure" that I remember, however there may be some that I have forgotten.

The OP's trailer is a 2015 Cougar 28RBS, which is a 31' travel trailer, so "upper deck movement" wouldn't be the issue. I can't find any previous recall information on his trailer frame.

[Ken / Claudia]

I do not have much knowledge about metal but, could it be caused by poor or wrong metal used. If that is possible maybe a inspection of the whole frame would be in order to prevent further problems in other areas of the frame. Glad you found it before a incident happened on the road.

[340_Formula_S]

Well, I'm no smarter than the next guy, I guess I was just lucky that somebody else was looking after me. You see too many of these types of situations that played out to their conclusions on the highways.

[Mr30RLI]

340

As a 2015 30RLI owner I am very interested in seeing the damage you are talking about and also knowing how Keystone addresses it.

Sorry you are our test case but please keep us updated on this.

Can you post some before and after repair pics please?

Frank

2014 Tundra SR5 4X4
2015 Cougar 30RLI

[340_Formula_S]

I am going to fix it myself through a local machine shop. I will post some pictures when we get started. Right now I'm not able to show you anything other than the temporary repair that I had made to get me home. I will have to cut that off with a grinder to make the final repair. I will, at that time, try to get a picture of the actual crack.
If Keystone wishes to reimburse me that cost, that would be a plus, and they should, however, I know what I want done and that's what I'm going to do.

[tommyboy123]

What about the pics

[bsmith0404]

Just a thought, it seems obvious to me that this MAY be an overloaded stress point on the frame. Not saying you overloaded it, speaking more in reference to design. I've seen so many repairs (not necessarily on RVs) lead to exposing a "new" weak point. If it were me, I would beef up both sides since that area of the frame is exposed to the same/similar stresses.

[340_Formula_S]

Originally Posted by bsmith0404

Just a thought, it seems obvious to me that this MAY be an overloaded stress point on the frame. Not saying you overloaded it, speaking more in reference to design. I've seen so many repairs (not necessarily on RVs) lead to exposing a "new" weak point. If it were me, I would beef up both sides since that area of the frame is exposed to the same/similar stresses.

I do intend to do both sides. You are absolutely correct, to fix only one side would obviously point toward the other side as the next point of failure.

[cabinfever]

I would also have the fab shop give you their opinion on the entire underside, axle mounts, rear bumper mounts, anything welded, etc. Might as well be proactive while you are there.

[hankaye]

340_Formula_S, Howdy;

Please take a s many pix as you can of the tear and the repair process,
not only for us to look at but as a aid to your up coming communications
with keystone.
thanks.

hankaye

[340_Formula_S]

It's not the easiest to see but here is the cracked area after the temporary repair was removed today. I had the permanent repair made today and will get some pictures in the morning to post.

[cjm]

I had a similar crack on a 2012 282BHSS trailer, last year. Keystone covered the cost to repair without hesitation. It was rather refreshing ...

[340_Formula_S]

Completed repair: 3/8" steel plate x 18" long. Welded on all four sides and cut to fit inside the frame rail. As discussed, I did both the torn side and the un damaged opposite side.

[chuckster57]

Nice repair. Make sure to cover that burnt fabric with some underbelly tape or gorilla tape.