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Old 05-02-2015, 04:35 PM   #1
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2015 28' Flying Cloud
Charlottesville , Virginia
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Newbie Disappointed in AS Quality

My wife and I purchased a new 2015 28 Ft. FC last August. We love the trailer but we are disappointed in the quality. We continue to have hinges that come lose and plastic hooks that hold the cabinets closed that have screws come out. How do you screw them back in so that they are secure? The cabinet wood isn't real wood it is pressed board or some type of composition material I think that is why the screws vibrate lose. The plastic door hook that holds our medicine cabinet closed came lose and the hinge at the top of the medicine cabinet has also come lose. The plastic door hook on our closet next to the refrigerator has the screw come lose as well as a screw that holds the hinge to a cabinet in the BR came lose causing the door to fall off. I know that these trailers bounce down the road but there should be some way to keep the screws that hold the hinges and latches from coming lose. Can someone tell me what type of "wood filler" to buy so that the screws can be put back and tightened? I'm frustrated that so many screws and latches are malfunctioning. Is this just our unit or have other owners had the same problem? Any help/advice that others can give me will be greatly appreciated. We are leaving in less than two months on a six week WBCCI caravan and these items need be fixed before we leave. I don't mean to rant; we love the AS forum and every AS owner whom we have met has been friendly and helpful but we are disappointed in the quality of our AS.
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Old 05-02-2015, 04:41 PM   #2
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I would check the hitch. What brand do you have? I am guessing that you have it set up wrong and are shaking things badly. Do you see any rivets loose on the inside or outside, and items moving around in the trailer?
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Old 05-02-2015, 05:35 PM   #3
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I usually try inserting a broken off toothpick into the hole then along with some type of glue I screw that screw back in. More often then not this will work.

PS...for the cost I agree that the quality control should be much better.
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Old 05-02-2015, 05:40 PM   #4
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If the tooth pick doesn't work you can use a wood dowel, slightly larger than the current hole, drill out to the dowel size and glue it in place. Then do a starter hole for the screw.
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Old 05-02-2015, 05:45 PM   #5
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Are you Towing with a Dually ?

Are you able to take it in for service/warranty work ?
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Old 05-02-2015, 05:51 PM   #6
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I think CBWELL has a point. You haven't said what your TV is or the details of your hitch set up. For example, when I first got my 2009 27' FB, I was towing with a F350, a very stiff suspension. Add to that I had 1200 lb rated bars which the combination was killing the trailer. I switched to 600 lb bars and life was a lot better for me and the trailer.
That being said, simple wood screws in particle board are a design for failure in a trailer. Where ever I can, I replace them with machine screws backed with as large a washer I can fit and nut and lock washer. The top hinged mirror in the bathroom is a prime example. So many, including me, have forgotten to release the hinge lock on the left hand side and blown out the wood screws in 1/2 inch particle board.
Warranty should cover the items you've listed. Take it back to the dealer.
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Old 05-02-2015, 06:09 PM   #7
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Tucson , Arizona
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I think you're gonna learn a whole lot on the Caravan. The quality of your AS is just like every other AS, but your experience is not. So what are the variables? I would suspect the hitch set-up as CBWELL observes. Not the hitch, the set up. Also $200 invested in Centramatics - call Andy on that one - will make a world of difference. Maybe past driving conditions contributed - last year while on a 45 mile dirt road detour, I was going about 15 - 20 MPH and a yahoo came around me at 50 or more.
Not saying you would do that, but speed on US 99 in California will bust your teeth.
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Old 05-02-2015, 07:17 PM   #8
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evergreen , Colorado
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After 2 years and several warranty fixes, the screws still are still falling out; the dowel insert is a good solution. I complained to AS sales VP at Denver RV show. He said it was an unusual list of system failures, including some minor screw malfunctions . We were surprised at the 17 problems we encountered in the first 18 months.
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Old 05-03-2015, 07:35 AM   #9
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Charlottesville , Virginia
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Tow Hitch and Tow Vehicle

Thank everyone for your suggestions and questions about my AS quality post. I am towing with a Hensley Hitch with 1,000 lb. bars. I do have a new tow vehicle, I originally towed with an Infiniti QX 56 I recently purchased a GMC Denali 2500 Diesel. The problems with loose screws has occurred with both tow vehicles although they seem to be worse with the new truck. Originally when we purchased the AS we would find screws on the floor of the trailer after towing the trailer. Right now we have the bathroom mirror with loose screw that holds the hinge at the top and a loose screw in the plastic latch on the right side of the mirror. We have twin beds, with two small closets at the foot of each bed. The door to one of the closets came off due to a screw that came loose on the top hinge. There is a trap plywood door beneath the cushion on the dinette, the trap door has a piano hinge every screw in the hinge has come out, and there is a strip of wood 2 X 2 under the plywood seat in the storage area that fell off we found it on the floor of the storage area under the dinette seat. The closet beside the refrigerator had a screw come loose that held the plastic latch. That plastic latch has on that door is broken. This is not acceptable quality the trailer was purchased on 8/11/14 and was stored and unused from 11/1 until 4/15/15. It has been towed approximately 5,000 miles all on interstate highways.
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Old 05-03-2015, 08:01 AM   #10
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Hot Springs Village , Arkansas
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I have the same trailer, only ours is a 2013. Have not had any problems similar and I also tow with a 2500 Duramax. I do have an Airsafe Hitch in addition to my Equalizer and I do believe it gives the trailer an softer ride. Especially over rough expansion joints, railroad tracks, etc..
Check out the Airsafe website for more info.
There are others on the forum that also use the Airsafe.
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Old 05-03-2015, 08:08 AM   #11
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I'm gonna second the need to ensure your wheels are balanced. I'm in the process of changing the headliner in our 2002 Bambi. Once the old headliner was removed I was truly shocked at the number of interior ceiling rivets that have sheared off - the only culprit that comes to my mind to cause this would be wheel balance.


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Old 05-03-2015, 08:19 AM   #12
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Ed, we want to help! So, thanks for giving timely reply.

So, are you towing your AS level or nose up/down?

Have you weighed it? Was it fully loaded or dry? Do you tow with water in the fresh tank?

Have you taken the AS and had the running gear balanced? What is your tire brand and wheel size? Tire pressures? What speed?

For those of us who have older AS, this is merely annoying stuff. Yes, from mild to insanely annoying.. And, actually I can imagine how you feel about it.

Our AS is a bit out of warranty, it is all on us...to maintain and repair. So we must ask for help then apply the creativeness of this group balanced with my lack of talent.

In your case, I would insist on repairs by AS. Yes, repairs at dealers cost time and money... But it is documented in event of a lemon law or more civil recourse.

Regarding the cabinet quality, the "green" folks may say "sustainability"... I prefer another word beginning with "s" for that "stuff". No manufacturing is perfect and unless you report to AS, the problem will never get resolved by them.

If you plan to keep the AS "forever", fix it yourself. Use adhesives to strengthen the wood to screw adhesion. Put a dowel as mentioned above. This will give a wider bonding area to the cabinet and better wood for the screw to grab.

If you add a toothpick to the hole then drive the screw, you might put too much pressure and cause a bigger hole or split the wood. So ask about each fix you envision. There are some great wood workers on the forum who can help!

A final thought... If the screws have been overtightened at AS, stripped out wood material from the hole, the same screw will never stay in. This is where you may be able to add some toothpick or other wood with a bit of glue to see if it will hold ( usually this gives a great, long term fix.

Let us know!!!
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Old 05-03-2015, 08:48 AM   #13
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If possible I would consider warranty at dealer. Primarily because the quality issue gets back to airstream. However dealers are not always convenient and in my case 500 miles away. Wood golf tees work good, they are already tapered. Tap lightly cut off to length. Works on screw holes nicely. I feel your frustration.


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Old 05-03-2015, 09:29 AM   #14
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I suspect the hitch is not set up correctly. Your comment about more problems after getting the new truck almost confirms my thinking. The 2500HD has a lot stiffer suspension than the QX. Call Hensley and explain to them what is happening and ask for suggestions. I am not familiar with the Hensly/ProPride, but maybe some owners of these hitches could give some insight and help. As others have mentioned, check the tire balance. Good luck and keep us posted. Chris
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