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Old 07-04-2018, 04:48 PM   #21
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Same issue on my 2005. Found this last year. This the the middle mount, which was not lined up properly and causing it to pull. Ended up unbolting and sealed crack. With it unbolted from guard the crack has stopped spreading.
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Old 07-04-2018, 08:09 PM   #22
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I had JC Service Center remove my battery boxes after Lithiums were installed under the queen bed. While doing it they reinforced all the structure as mentioned above without me asking. Also, during a routine wheel bearing repacking frame cracks were observed. Three on one side and two on the other. Of course, they welded them up and on a receint visit the same tech checked his welds to make sure they were holding. They were, and I was impressed with their careful inspecions while doing other work. Folks, the Interstates are slowly trying to reduce our rigs to rubble. Although I see lot's of Interstate reconsrution and repair going on, I am afraid, in the longer run, it is a losing proposition. Too much population growth and too little money to keep up the needed repairs.
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Old 07-05-2018, 08:36 AM   #23
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All the cracks in the photos I've seen here appear to me, to be caused by vibration of the rock guards causing the skin, which the bracket is attached to, to work harden and crack. Stop drilling alone will not fix the problem. At a minimum a patch around the damaged area will be required. I am always mystified as to why Airstream continuously attaches components to the skin with no reinforcement, and etc, etc, etc,.
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Old 07-11-2018, 11:06 AM   #24
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crack in Aluminum

Two possibilities come to mind. Depending on the visibility, you might use JB weld. It's a very good product for metal repair can be sanded and paintable.
However it is a dark color and may be a distraction if visible.
#2, is aluminum welding.
Good luck.
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Old 07-11-2018, 01:24 PM   #25
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drill the end with 1/16" bit and fill with sika-flex. this is how an airplane would be repaired.
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Old 07-11-2018, 05:05 PM   #26
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I had the same problem...in the same place. Try Steelstik by JB Weld. It's a metallic epoxy. Just knead together, press it into the crack, and remove the excess.
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Old 07-13-2018, 03:31 AM   #27
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Quote:
Originally Posted by thecatsandi View Post
drill the end with 1/16" bit and fill with sika-flex. this is how an airplane would be repaired.
I DON'T THINK SO... but nice try... with the sika flex... what a mess it would turn out...
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Old 07-14-2018, 07:45 PM   #28
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Quote:
Originally Posted by Aerowood View Post
All the cracks in the photos I've seen here appear to me, to be caused by vibration of the rock guards causing the skin, which the bracket is attached to, to work harden and crack. Stop drilling alone will not fix the problem. At a minimum a patch around the damaged area will be required. I am always mystified as to why Airstream continuously attaches components to the skin with no reinforcement, and etc, etc, etc,.
I’m not a metal guru or and airplane guy but I agree with Aerowood’s advice. I also happen to admire a well done patch. My preference is a flush patch but you would need access to both sides of the aluminum to accomplish this. So instead I would suggest a lap patch.

Carol

You can read more about patches here: http://okigihan.blogspot.com/2017/06...structure.html
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Old 10-14-2018, 12:40 PM   #29
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It looks, to me like the Right side of the bracket is pulled up and away from the skin, and the crack is coming out of that lower right side rivet hole.
That would make sense, as the bracket is probably being flexed by a misaligned rock guard.
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