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John&Vicki · 05-19-2014, 05:36 PM

A couple of cracks appeared in the front end cap in my '90 Excella 25 footer. I have done quite of bit of research here before posting, but I'm left with some questions as I know enough to be dangerous.

One crack is fairly large and I'm concerned about structural integrity. As you know, there are two oak cabinets built into it. We haven't had anything heavy stored there and I've lightened it further. I also got a couple of nickel shower curtain spring loaded rods to prop things up for the trip home (actually almost look as if they're meant to be there) - no expansion of the crack on the way home.

I was concerned about what caused the cracks. My research here has uncovered that the problem seems to occurred in a number of trailers around my vintage, so perhaps it's a production or design issue. I don't think I have excess vibration: 50lb tire pressure, axles seem fine height wise, no loose rivets or other signs of shaking.

I'm not concerned about cosmetics as that seems easy to fix. But I am worried about structural issues. Is the end cap load bearing? Does it support the oak cabinets or do they have some other means of support?

Thanks to many informative posts I think I have a good idea of how to repair the cracks themselves in terms of materials to use. However, some recommend removing the end cap and some recommend removing the cabinets and accessing it from the inside. I'd appreciate advice from those who have tackled this project - and I'm really hoping it can be done without removing the cap.

Thanks for your help!

Poppy

featherbedder · 05-19-2014, 05:52 PM

Quote:

Originally Posted by Birdmaestro

A couple of cracks appeared in the front end cap in my '90 Excella 25 footer. I have done quite of bit of research here before posting, but I'm left with some questions as I know enough to be dangerous.

One crack is fairly large and I'm concerned about structural integrity. As you know, there are two oak cabinets built into it. We haven't had anything heavy stored there and I've lightened it further. I also got a couple of nickel shower curtain spring loaded rods to prop things up for the trip home (actually almost look as if they're meant to be there) - no expansion of the crack on the way home.

I was concerned about what caused the cracks. My research here has uncovered that the problem seems to occurred in a number of trailers around my vintage, so perhaps it's a production or design issue. I don't think I have excess vibration: 50lb tire pressure, axles seem fine height wise, no loose rivets or other signs of shaking.

I'm not concerned about cosmetics as that seems easy to fix. But I am worried about structural issues. Is the end cap load bearing? Does it support the oak cabinets or do they have some other means of support?

Thanks to many informative posts I think I have a good idea of how to repair the cracks themselves in terms of materials to use. However, some recommend removing the end cap and some recommend removing the cabinets and accessing it from the inside. I'd appreciate advice from those who have tackled this project - and I'm really hoping it can be done without removing the cap.

Thanks for your help!

Poppy

What I have found is pop rivets to close edge of cap. I replaced mine short time later cracked again, drilled small hole at end of cracks, cracked further, gave up live with it. I don't feel like drilling all rivets out take cap out then repair from back side, once is enough. Some have repaired w/out removing cap maybe they will tell how. Bill

John&Vicki · 05-19-2014, 06:52 PM

Thanks for the reply Bill. I don't mind living with the cracks or fixing the end cap cosmetically only - but I am worried about structural aspects. Does it support the weight of the oak cabinets? Is it possible for it to crack so severely that it could fall apart?

Poppy

featherbedder · 05-20-2014, 06:36 AM

Quote:

Originally Posted by Birdmaestro

Thanks for the reply Bill. I don't mind living with the cracks or fixing the end cap cosmetically only - but I am worried about structural aspects. Does it support the weight of the oak cabinets? Is it possible for it to crack so severely that it could fall apart?

Poppy

I have 76 AS end cabs are molded into cap with tambor doors
so I can not answer as to structural aspects & I do not keep any heavy items there. Bill

John&Vicki · 05-20-2014, 07:22 AM

Can anyone with a '90+/- era trailer add information?

Thanks,
Poppy

Jeepjunk4 · 05-27-2014, 09:56 PM

I have a 1990 29 footer and have the same problem. I have tried to find a solution on here but no luck. I have replaced my axles and just got back from a 1500 mile trip and the cracks are getting worse, and the back cap is worse than the front. I really don't want to get involved now, but I may have no choice. The only thing I can think of is somehow glassing or gluing it from behind.

featherbedder · 05-28-2014, 07:10 AM

Quote:

Originally Posted by Jeepjunk4

I have a 1990 29 footer and have the same problem. I have tried to find a solution on here but no luck. I have replaced my axles and just got back from a 1500 mile trip and the cracks are getting worse, and the back cap is worse than the front. I really don't want to get involved now, but I may have no choice. The only thing I can think of is somehow glassing or gluing it from behind.

Drill 1/8 or 3/16 hole at end of crack probably will stop spread, will gain some time until ready to repair, mine has been this way for yrs. Bill

Jeepjunk4 · 05-28-2014, 07:42 AM

Thanks Bill. I will do that. Im reading horror stories about it being a pita to get the cap back in after removal, so im not looking forward to doing that. It does look to me though that the cabinet is just a face plate on the cap, im not really sure.

nm1oqrz · 05-28-2014, 08:52 AM

Hello JeepJunk4. On my 88 25' I had a crack and decided to remove the endcap. It wasn't hard just time consuming drilling out all the rivets for the small panels that were in the way, disconnecting the radio ect, removing the curtans and blinds Once removed I drilled stop holes and then fiberglassed from the inside over and cracks. Putting it back in needed 2 people to get it positioned and then once a couple of rivets were installed it was just poping a rivet into each hole and putting back all the panels and blinds. Just time consuming.
Good luck
Happy camping nm1oqrz

Jeepjunk4 · 05-28-2014, 12:15 PM

Thanks nm1. Im kinda getting into it now. It doesn't look that impossible, like u say time consuming. My front cap has a couple of small cracks that don't seem to be getting any worse but the back cap has the electrical panel in it and that seems to be wobbly too, the rivets holding it in aren't very tight, so I think I need to see how I can get that back and secured, because besides that there really is no weight in those cabinets. That's the cabinet Im really concerned about right now.