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Roundtowner's avatar
Roundtowner
Explorer
Sep 02, 2014

Chalet with a rotted basement floor

I'm looking for information and causes from others (especially Chalet owners) that have experienced a failure of their TC basement floor from rot (from being wet or dry rot?).
I have a 2012 Chalet TS116 that I unloaded from my truck last week. I noticed that the basement floor sagged down/dropped down a couple inches. I quickly pumped dry the fresh water tank to lessen the weight on the floor. (I had previously emptied the black and grey holding tanks.) I can feel that the wood (plywood?) bottom is soft and broken. The black plastic membrane covering the bottom is stretched but not compromised, punctured, or broken and has not failed. I think it is the only thing holding the floor and the tanks from falling out.
I sent photos to the factory and ask if others have experienced this problem. When I called and spoke with the manager, he said that they have no knowledge of any other unit having a problem such as this and no idea as to what the cause could be.
I have traveled over 15k miles and 100+ nights this year with no known issues. In nearly all of my travels, I have boondocked and would have learned of any leaks in my supply plumbing(loosing pressure, pump running when not in use, or tank level loss). I can not see any wet spots, although it's not possible to see under my fresh water tank or up far into the basement area. I can only surmise that perhaps I have bath sink or shower drain leak or a fresh water fill line leak that is not large enough to notice. Again, I can't see anything to indicate a problem. Yet, it is only two years old and I can't imagine such a catastrophic failure from a simple issue or that I'm the only owner to have such a problem.
Chalet wants me to take it to the factory for repairs, take it apart, and then determine who bears what costs based on what they find and have to fix. That would be a trip of over 5000+ miles and a month my time.
Thus, I'm trying to gather any and all information that can help me troubleshoot and find the problem. Then, maybe I can make a better decision as to what to do and how to approach fixing this serious problem. Any and all inputs are welcome.
Sorry for the extra long post and thanks for your insight and replies. Larry

15 Replies

  • this was the source of a very low volume leak in my Chalet I was lucky and caught it early and there is no structural damage

    ps Bill Penny told me to check the area under the Fat rack mounts

    also check the mounting bolts on your awnings on some ,the (a extremely poor design :M ) bolts go through the rain gutter into the aluminum framing creating a easy path for water intrusion to travel long distances undetected
  • So sorry to hear of your problem. It sounds more like a major structural failure in the floor area. Its hard to imagine that you would have that much rot in just 2 years, plus like you mentioned I would think you would of seen signs of water leakage at some point during its use, especially to cause that much rot in such a short time span. I hope you can find a solution. Being I also live in the east I can feel for you and realize how inconvenient a repair trip to the factory could be.
    Maybe try someone like Truck Camper Warehouse in NH (also a location on Long Island) since I know he is very familiar with TCs and he sells Chalet. Plus he does do some pretty major repair work.
  • sorry to read about your problem.

    I'd like to ask about something:

    Did you or the dealer add bump-stops to the front of the bulkhead to keep the camper from pushing into the front wall of the trucks bed?

    When Jim Allen was the head of Customer service at Lance Campers he told me that the biggest reason for rot like your campers (and most expensive to repair) was when people added bump stops with lag bolts and the lag bolts punctured the water tank... the leak was slow enough to not be noticed, and steady enough to keep the bottom and lower front of the bulkhead wet 24/7. Within 2 years there would be so much rot that the structural integrity was comprimised. The owner was responsible for paying for all of the repairs,

    And I'd like to suggest:

    Map your external rot as much as possible... there might be more than you think.

    Take an Ice pick and press it into the wood, it will go in easily where rotted (limit your push to about 3/4") It will barely go if there is no rot.

    Best of luck,


    Sleepy
  • Do you have pictures?
    Where the camper was bought? And when?
    Do you flush your black tank? If yes, do you winterize the line?
  • I am so sorry you have to deal with this. I had a similar problem with a TT a few years back. There was even talk of a class action suit against the maker. I would have the local chalet dealer take look first. Try to get an idea before traveling all that distance.