Frame failure

[Mikendebbie]

I don’t think we (the Montana forum members) have any statistics on frame failure/broken stud welds/etc etc etc…by model or by year. I suppose failure could happen to any unit/year/model.

I seem to remember that Legacy unit had a deeper/larger/heavier main frame members than High Country models, but frankly, I don’t recall a thread discussing member sizing or detailed differences since I have been a member in 2018. I have no idea if the heavier frame translates to fewer frame failures. A broken weld or outrigger could happen on any unit I suppose. I have no idea if newer High Country models have a larger frame than the used to have.

I have an un-verified opinion that my unit may have more “beef” in the drivers side front wall at the slide hole to guard against a stud failure around the bed slide due to the position of the bed slide. The big hole in the wall for the slide in my unit is farther back from the nose which provides more wall/framing around the slide hole on all sides. Units with slides closer to the nose have less “beef” around the hole. Maybe the design engineers provide more studs to make the wall stronger around the hole…I have no idea. The engineers added a control joint to allow some movement in the wall without cracking the fiberglass. Just my opinion.

Maybe you should expand your search to include used Legacy units with a similar floor plan. I would be looking for a pre-Covid unit in a Legacy model if I were in your shoes.

[LarryBessette]

Unfortunately not. Not knowing which came first, the broken welds or the bent frame I would have to drop the underbelly to look and I doubt anyone would permit that.

[LarryBessette]

Insurance company denied my claim. They said that the welds are defective and it's a manufacturers defect.
I guess I will contact Lippert again and Keystone. See what they say.

[LarryBessette]

OK, here we go. I have a local shop fabricating my components for the repair.
2-8' 5"x 5" square steel tubes to straighten and reinforce the frame. 5 new cross members made from #11 sheet (OEMs are #14 sheet). New outriggers, Again made from #11 sheet. This week it is going to be warm enough for me to get under the unit and start cleaning the areas where the new components will be welded in. I will probably get the parts late this week or early next week.

[Daryles]

Sounds like a good plan.
I would especially Reinforce cross beams over the front and rear leaf spring hangers. They take the most flexing when backing into a 90⁰ site.
This is a picture of the broken weld on the cross frame support over the left front leaf spring hanger

Take lots of pictures.
Keep us informed.

[LarryBessette]

Will do. The tough part is getting the frame straight

[LarryBessette]

I have been working on the frame of my camper. 1st day was cleaning the frame so that the 5x5 square tubes would go in tight against the frame rail. Then a friend helped me set the 5x5s and brace them in place (pics 114958 and 115017) Second, third and fourth days I clamped, drilled, twisted and jacked until i got the 5x5s bolted in place. It was amazing how much better the frame looked. But I wasn't done. There were still three places i wasn't happy with, the rear spring hanger on the left side, the center hanger left side and the rear hanger right side. All three had noticeable bends that had not come out with the bolts that I had installed. today I drilled through the 5x5s at the very bottom. this allowed me to install bolts at the critical points to pull the frame into place. The result is better than I anticipated. The bolts thru the bottom of the 5x5s pulled the bent areas into place. Now the frame is straight ( pics 131010 and 133850) And I can begin installing the cross members. Its been a job but so far the results are better than I imagined.

I'll get more and better pictures tomorrow.

[Daryles]

Damn that looks great !!!
Are you going to run a bead of weld around the 5x5 ?
Add reinforcement angle to your leaf spring hangers.

[LarryBessette]

I'm going to stitch weld at the critical areas. I think I am going to install the X-factor braces mentioned in some earlier responses. They look like they would add additional frame stability.

[LarryBessette]

Only had a couple of hours to work on the camper today. Got the frame that supports the black tank fixed and back in place. Also got the first cross member in place.
tomorrow my plan is to weld what I have in place, install the other two cross members and weld them in place.

[twindman]

Frame Flex USED TO BE when the over hang at the front would sort of come apart. At the corners where it goes up and then forward again, the welds would break. I am not sure but I don't think they even had any gussets on the corners or if so they weren't very thick. I had this happen around 20012 on my 2006 Monty. Shortly after or around then, Montana went to bigger frames, I think 10 inch up to 12 inch Ibeams. I think that is what they have now but the High Countries are only 10 (which holds the weight down).
Now people are calling frame flex when welds break on side walls, etc. To me that is not really the frame - just the studs. I had this happen on my 2013 also. Back wall sort of detached at the bottom and move about an inch rearward. Turns out on both sidewalls, there are short vertical studs and 3 of mine broke.

I guess 2 trips to Alaska does wonders for the frame. LOL