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Old 01-15-2020, 09:27 PM   #1
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2019 30' Flying Cloud
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Aluminum Ceiling Split

My wife noticed the aluminum in the corner above my refrigerator. Anyone have any suggestions on fixing this problem?
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Old 01-15-2020, 09:33 PM   #2
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I have read you should drill a hole at the end of the tear to stop it
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Old 01-15-2020, 09:37 PM   #3
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Aluminum Ceiling Split

Your profile suggests this is a 2019 trailer yes? If so - I would start by contacting AS service by email with the pics to get a read and to get it on record during the warranty period.

Fixing could range from the fun/simple/inexpensive/creative - namely, a funky aluminum patch - to the tedious/complicated/expensive/perfunctory - namely a factory tear down and reinstall of fresh aluminum.

Understanding the root cause is critical here. Was there a materials and/or manufacturing/assembly defect? Was it a tiny crack that got bigger with road vibrations or perhaps an over-aggressive hitch setup?

Lots to explore here but start by contacting the factory for their read.

Good luck!
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Old 01-17-2020, 02:19 PM   #4
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The most likely cause is a stress point on the skin from the point contact of the cabinet corner from the trailer flex. Not sure how Airstream will fix but I would trim the corner to relieve the stress point and repair the panel with a round patch.

If still under warranty I would insist on panel replacement and a rework of the cabinet corner.
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Old 01-17-2020, 02:49 PM   #5
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Should there be the same plastic trim above the fridge?
It appears that all the weight of the ceiling panel is supported on the corner moulding, thus it split.

After Googling, it appears the plastic trim is not used over the fridge, only the curved sections. However, I stand by that the wood corner is pushing on the ceiling panel, causing a stress point.
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Old 01-17-2020, 03:24 PM   #6
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So, if I was 'fixing' it I'd get a (sacrificial) strip of aluminum, slide it between your ceiling and the post, (to avoid scratching your ceiling) then try to shave the post in place with a cutting tool, the Bosch multifunction tool.
After the stress is taken off the corner of the wood moulding, the ceiling panel might lay flat again and the crack become less noticeable. Only you can decide how much is 'okay'.

Or let Airstream deal with it.
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Old 01-17-2020, 06:48 PM   #7
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Drill a very small hole at the end of the split. Called "stop drilling". Used on old airplanes all the time on non structural parts. If you don't drill it the spilt can continue to run.
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Old 01-18-2020, 07:20 AM   #8
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**Update**

Talked to JC and they said it would be covered by warranty and would be a replacement of the panel. Just need to work out the details on an appointment that doesn’t interfere with our travel plans.



We did drill a hole to stop the tear and put small rivet in it. Thanks for the suggestion.

Also, agree that the corner post pushing up on the aluminum caused the tear.

Thanks again everyone for the suggestions.
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Old 01-18-2020, 08:43 AM   #9
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Quote:
Originally Posted by Dreaming3 View Post
My wife noticed the aluminum in the corner above my refrigerator. Anyone have any suggestions on fixing this problem?


Before you do anything to it. Contact AS with a written letter and lots of photos. If under warranty let AS handle it.
I agree with others it appears that the cabinet is putting pressure on the aluminum panel. That’s AS problem of installing the cabinet in a way that caused the stress point. If you go with a “stop drill” fix you need to in sure that the cabinet caused stress has been fixed. Then you can “stop drill” the crack. First you must fine the end of the crack, then drill a hold at the end of the crack at least using a #10 drill to insure you eliminated the end of the crack. In one of the photos it appears that one side of the crack is higher than the other side, this could show that the cabinet is pushing the misalignment. That’s why I said that the cabinet could have been installed wrong and this condition must be fixed before fixing the crack. But one caution towing the trailer will cause the crack to grow.
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