TH Ramp Door Problem

[arhayes]

As background, we have full-timed in our 380TH since August of 2014 and have probably unloaded and loaded our Goldwing 150 times. The chock is in the center so the bike is always run up and down the center of the ramp door. I've previously noticed some softness running down the top center of the door, but in unloading recently discovered that it was much much softer than before. Today after unloading my wife was walking up the ramp and there was noticeable flexing along the top center section. It feels firm once you get past a 6"-9" from each side of center and about 3' down from the top of the ramp, so the entire door does not appear to be affected. Once I secured the door closed, I also pushed on the exterior and the softness can again be felt in the same general area as well. It's obvious that the foam in the bond has broken down in that area.

I contacted LCI who makes the door for Grand Design (and many other Toy Haulers and trailers) asking if there was any repair advice. They, of course, told me the door needed to be replaced ($1832 + $800 shipping + who knows for ancillary parts, plus whatever someone would charge to install it). I'm currently using a temp 24" x 60" piece of 3/4" plywood I had from another project when I load/unload the bike. Before I drop 3 bills on a new one, has anyone else experienced this AND come up with a suitable repair that they have confidence in? I know I cannot be the only one this has happened to.

Thanks in advance.

[nayther]

never gave it a second thought; loaded my Wing a couple of times, rode it right in and out.

[tinner12002]

arhayes wrote:

tinner12002 wrote:
Check with Challenger as someone already gave you the link to them but when I load my bike I lay a 7'x 2' pc of alum tread plate down to spread out the weight some.

Challenger is on my list to do. Good idea on the tread plate. Do you attach it someway or does it have a nonslip surface on the bottom?

No attachment, I just lay it on the door and let the frame at the bot of ramp, when open, hold it from sliding. You could attach it I guess but that would make the door heavier to open and close. I usually just slide it in under or between the bikes after they are loaded.

[DynoDragn]

Ramp door

Saw this while browsing if anyone is interested. Says free shipping and has the patio kit.

[RideSlow]

tinner12002 wrote:
Check with Challenger as someone already gave you the link to them but when I load my bike I lay a 7'x 2' pc of alum tread plate down to spread out the weight some.

Nice idea, my Ultra is heavy, and I wondered what I could do to mitigate the weight a bit.

[arhayes]

tinner12002 wrote:
Check with Challenger as someone already gave you the link to them but when I load my bike I lay a 7'x 2' pc of alum tread plate down to spread out the weight some.

Challenger is on my list to do. Good idea on the tread plate. Do you attach it someway or does it have a nonslip surface on the bottom?

[tinner12002]

Check with Challenger as someone already gave you the link to them but when I load my bike I lay a 7'x 2' pc of alum tread plate down to spread out the weight some.

[arhayes]

azdryheat wrote:
It's my understanding that the two sheets of 4x8 plywood join down the center of the ramp. I believe these ramps were meant for quads and such, not 900 pound touring bikes. If you have the patio option you have a thin sheet of metal on top of the plywood. Try moving your chock off center.

I'll have to check with Lippert on the overall construction and center seam, but if you are right, the failure makes perfect sense. The way our garage is layed out with a permanent desk on the street side and a floating desk with hanging drawers on the curb side, I have myself pretty locked into reinforcing the center as y-guy suggests below. Perhaps a sheet of something more substantial than plywood run down the center and coated with non-slip material?

[dedmiston]

Can you shop around? Are there local places that stock ramp doors?

[Y-Guy]

If az is right could you put down a 2' wide plank that's coated with non-slip to spread the weight?

[azdryheat]

It's my understanding that the two sheets of 4x8 plywood join down the center of the ramp. I believe these ramps were meant for quads and such, not 900 pound touring bikes. If you have the patio option you have a thin sheet of metal on top of the plywood. Try moving your chock off center.

[arhayes]

Y-Guy wrote:
Here are a couple recent thread that might help you.
Anyone do a total rebuild of a TH ramp?

New toy hauler ramp door!

Awesome. I'll take a look at these. Thanks!

[Y-Guy]

Here are a couple recent thread that might help you.
Anyone do a total rebuild of a TH ramp?

New toy hauler ramp door!