I just noticed that with the fiver unhooked I have a separation on the curb side near the front cap. The material under the overhang surrounding the king box is dropping away about 3/4 of an inch where it meets the side. The scary part is that when I hook up the truck and put weight on the king box it closes up. I took down the trim insert on the underside and tightened the screws. It closed up a little but not much. I fear a broken weld up in the framing. Any thoughts or suggestions? I will try to post pictures.Thanks AL

Not good...who needs this kind of grief.If you go to the link below you will see many examples of failed welds on frames...and how they were fixed.Probably going to be a trip to a local welding outfit.Broken Frame Images...LINK

Find a good welding shop and make sure they brace it with extra metal. I've had several Lippert frames and know they are made pretty cheap.

I have had 3 fivers and not one with a Lippert frame, I am on the forum consistently and read these frame issues and wonder why consumers continue to buy products that are inferior at the start. I guess it is best to just keep posting these problems and complaining maybe someone at Lippert will decide that it is time to stop the nonsense. Just because some people want a particular layout or are limited in the level of quality they can afford doesn't mean that they should get an inferior product. The manufacturers using the frames are the ones who can put the pressure on Lippert, but worry about pricing themselves out of a section of the market. Too Bad we settle for good enough.

Your 2005 falls right in the LIPPERT frame issuePull the overhang panel off exposing the pin box structureVisually inspect for torn cross sections, cracks, busted welds etc.Do this with trailer setting front landing gear legs (no pin weight) and hooked up to truck (full pin weight) Look for sidewall movement........and pin box flex

I'm running into the same problem on my 08 Cougar, except it's not the pin box. I just downloaded the PDF from Lippert and checked for pin box movement and there is none.My problem is the bottom of the bedroom closets are starting to separate and are bowing a bit on their sides. From talking with Lippert they are saying it might not be the frame but how Keystone attaches their aluminum framing to the steel of the frame, they use screws and they may be loosening or cracking.This is starting to look like a big job, insurance will pay for it but I can't imagine how well a local shop will be able to take the cap off and do a proper repair because it looks like all the bedroom cabinetry has to come out as well. Since this work is done before the frame is attached I don't know how they will!be able to do a decent job.I saw one picture of a failed repair attempt and they burned the camper down because they didn't remove the woodwork and the welding done under the cap area burned through to the bedroom !I have the insurance adjuster adjuster coming again today to look at it.Ron W

Broken Lippert weld? 2005 Cougar | Good Sam Community

JW_of_Opechee_S
Explorer
May 31, 2016
I have had 3 fivers and not one with a Lippert frame, I am on the forum consistently and read these frame issues and wonder why consumers continue to buy products that are inferior at the start. I guess it is best to just keep posting these problems and complaining maybe someone at Lippert will decide that it is time to stop the nonsense. Just because some people want a particular layout or are limited in the level of quality they can afford doesn't mean that they should get an inferior product. The manufacturers using the frames are the ones who can put the pressure on Lippert, but worry about pricing themselves out of a section of the market. Too Bad we settle for good enough.
kennethwooster
Explorer
May 31, 2016
Find a good welding shop and make sure they brace it with extra metal. I've had several Lippert frames and know they are made pretty cheap.
downtheroad
Explorer
May 31, 2016
Not good...who needs this kind of grief.
If you go to the link below you will see many examples of failed welds on frames...and how they were fixed.

Probably going to be a trip to a local welding outfit.

Broken Frame Images...LINK

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Broken Lippert weld? 2005 Cougar

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