Hallmark Ute XL needs front wall repair

[ardvark]

For those not familiar with Hallmark's Ute, the front wall has a 2" lip that juts out from the front wall and carries the jacks which do the lifting. The front corners on both sides are starting to pull away where the tub joins the upper section of the camper when the camper is lifted. Looking at it from the side it looks like that lip is loosening. To me this looks like a design flaw, but that's just my opinion.

I have not opened it as yet as I am trying to develop a repair strategy. I would like to do it myself and I do have the skill. I also know hauling it to Hallmark over a 1,000 miles away and having them make the repair will be pricey. The camper is an 04, but is overall in good shape.

Since the front wall is an atypical design, I am hoping to hear from someone who has already gone down this road. It looks like the fiberglass is glued to the front, so it is not as simple as just peeling back aluminum sheet and taking a look.

I know this must be due to water penetration, but the camper has been and does appear to be sealed well and has been stored indoors most of its life. Until I tear into the wall I can not find a sign of water damage inside or out.

I have debated just dumping it and starting over with another camper, but I really do like this camper.

[ardvark]

Got it done with 1 1/4" angle iron and 1/8" strap. Now have to pretty it up.

[ardvark]

okan-star wrote:
I had a 04 Outfitter did the same thing
The way the camper is built is kind of the same , because of the Ward family ties , Rory = hallmark , Bob / Brian = outfitter .
The "tub" they call it is built first and them the top of the camper is built on top , overhanging in front also , uncommon to most campers, making it prone to separate in front like that.
When mine did it they wanted to send me a tube of gorilla glue, LOL
It was caused in my case by the force of cornering and stress.
Put a jack under the tub of the camper with it on the jacks , while off the truck , you'll see the gap probably will tighten right up
My Outfitter was framed with very light aluminum , which made it harder to do , yours is wood which should make it easier , I used 1/4"thick 2x2 alum extrusion bolted to the overhang w/ plywood gusset behind the water tank inside , also 1/8" 1x1 angle running up the tub corners inside ,connecting to the same type angle running inside out twards the jacks , carriage bolted to the camper, tied together with a bolt where they crossed
Call Rory he probably has a method to fix it , and its not originally from water intrusion , but obviously can rot it left like that

Thanks, I was thinking along the same lines and agree the design guarantees much more stress where the tub is fastened than with more conventional designs. I haven't been able to find any sign of water penetration and feel like the way it is designed amplifies any movement from the roadway.

I have rebuilt walls on loads of fifth wheels and travel trailers, but have seen too many tear-offs that never got put back together to simply starting taking things apart.

Thanks again

[okan-star]

I had a 04 Outfitter did the same thing
The way the camper is built is kind of the same , because of the Ward family ties , Rory = hallmark , Bob / Brian = outfitter .
The "tub" they call it is built first and them the top of the camper is built on top , overhanging in front also , uncommon to most campers, making it prone to separate in front like that.
When mine did it they wanted to send me a tube of gorilla glue, LOL
It was caused in my case by the force of cornering and stress.
Put a jack under the tub of the camper with it on the jacks , while off the truck , you'll see the gap probably will tighten right up
My Outfitter was framed with very light aluminum , which made it harder to do , yours is wood which should make it easier , I used 1/4"thick 2x2 alum extrusion bolted to the overhang w/ plywood gusset behind the water tank inside , also 1/8" 1x1 angle running up the tub corners inside ,connecting to the same type angle running inside out twards the jacks , carriage bolted to the camper, tied together with a bolt where they crossed
Call Rory he probably has a method to fix it , and its not originally from water intrusion , but obviously can rot it left like that

[SidecarFlip]

Until you open it up, you won't know how it really is. Anyone can repair a unit, it all comes down to time spent versus value received.

You can sort of determine if it water damage even if there are no visible signs inside or out. Take an IR thermometer and shoot a side area where you know it's sound and then shoot the areas where you think it isn't. There will be a temperature difference between the maybe wet area and the dry, a couple degrees because the wet area has mold growing and mold creates heat.