Delamination of front cap of TT: cosmetic or structural?

Tom this is good info. I should have been more descriptive: my issue is manifesting itself as three approximately one foot depressions (not bubbles) where the front cap meets the roof.

Maybe he was using de-lamination as a word I'd understand? In any event, Keystone authorized the total replacement of the front cap (dealer's words) under warranty, and did so without any fussing. I assume that means they recognize some legitimate problem and are acting to fix it on their dime (which is good).

I'll ask them in any type of sealing needs to be done in that area between now and when we deaprt.

Curved front of a trailer like yours is not a laminated panel. The sheet of plastic forming the front is bent over a framework and fastened at the edges. If the panel did not fit just right, there can be waviness, flat spots where supposed to be curved, "bubbles" where it is supposed to be flat.

Since it is not a laminated panel, a dealer who tells you it is delaminating doesn't know what he is talking about, or assumes that you don't and is handing you a line.

It is not likely to be coming apart, but if the distortion is close to the top seam, you might be concerned about leaks at that seam. I would certainly have the seam inspected. The seam could be made highly unlikely to leak, even if trying to pull open, by taping over it with Eternabond.

This misfit of curved panels is common and usually just cosmetic. Bubble means the panel is probably slightly too wide and wants to bow up in the middle to fit between the sides. The repair is to pull the panel off the side seams, try to better re-fit it, maybe trim the width slightly, and hope it fits better when done.

One of the guys in our RV club had this problem with two TTs. First was an Aerolite, at the curve at the top of the rear of the TT. Dealer charged several hundred dollars to fix it, and it still didn't look right, so the guy traded it on a Keystone Sprinter. Rationale was "Keystone is a Thor company, Thor is the biggest so they must make good stuff." Yeah, but the Aerolite was made by Dutchmen, another Thor company.

The Sprinter had a curved front, and in a short time that got distorted at the top curve. This one buckled in slightly rather than buckling out, so rather than a "bubble" that could be passed off as delamination there was a flat spot in the center of the curve. Dealer inspected, found the seam intact, and they used that TT for another 3-4 years before upsizing to a fiver.

eDUBz wrote:
How bad does it look to you.? I don't think the dealer would get it done in time for your trip.

texasAUtiger wrote:
I'd classify it as minor to medium. Three bubbly looking spots where the roof seam meets the top of the front cap.

The real question is what caused the delamination - simply the adhesive letting go OR water intrusion? If it's the latter you'd certainly want to seal the area to prevent further damage as you're bound to run into rain on your trip at one time or another.

eDUBz wrote:
How bad does it look to you.? I don't think the dealer would get it done in time for your trip.

I'd classify it as minor to medium. Three bubbly looking spots where the roof seam meets the top of the front cap.

Dealer said it could wait until we returned. But then again, he likely can't fix it before we leave, so what's he supposed to say? And it's not his 33 day cross country trip with kids that hangs in the balance. (Perhaps I'm too cynical.)

I'm not a worry wart by nature. I just don't want to run a decent risk that we get stuck with a big problem far from home. Whatever the truth of the matter is, I can live with.

How bad does it look to you.? I don't think the dealer would get it done in time for your trip.

What did your dealer say?