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Old 03-02-2019, 04:16 PM   #1
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2017 20' Flying Cloud
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Surprised by poor quality sheetmetal Fab

The rear storage compartment gasket was a bit wonky and not seated on my nearly new 20' FC, so I pulled it away from the flange and discovered the obvious problem was that the inner aluminum panel was not attached to the door frame for most of the perimeter, and the inner panel cutout was very uneven and ragged looking. Both these conditions were keeping the gasket from seating.

I was able to clamp the two edges together and add rivets as should have been done originally, and then trim the inner panel edge smooth and flush with the door opening. The gasket then installed easily and properly.

Pretty surprised at how awful this looked. Hard to understand how an assembler would have such zero pride of workmanship, so maybe they need better tools ?
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Old 03-02-2019, 04:22 PM   #2
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Welcome to the inconsistent world of Airstream quality control.

https://www.google.com/search?q=QC+q...com&gws_rd=ssl
Senior Management Failures: http://www.airforums.com/forums/f542...as-182914.html
https://www.google.com/search?q=Qual...=airforums.com



PS — The good news may be that most RV manufacturers are said to be worse than Airstream.
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Old 03-03-2019, 06:41 AM   #3
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Does this mean we should settle for the "Best of the Worst"?
I wonder if A$ ever heard of a template?
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Old 03-03-2019, 08:42 AM   #4
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Photos

Seemed like the upload attachments was successful, but I don't see the photos as attachments so I will try again. In the image on the right you can see two "non-functional" rivets that just go thru the access door frame and do not attach to the inner sheet metal. I removed those rivets, clamped the joint, and added appropriate rivets.
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Old 03-03-2019, 09:10 AM   #5
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But they got it out the door and sold, huh?


That's what makes the bottom line. Quality doesn't seem to.
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Old 03-03-2019, 01:06 PM   #6
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Same problem with my 2017 FB 27 foot Int. Serenity. I have another annoying cut on my finger from the sheet metal. Healing slowly.
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Old 03-03-2019, 03:32 PM   #7
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IF you saw your new $150K Airstream ( insert celebrity ) without the windows and trim,you would have walked out on purchasing it,by the manner that they are chopped up.There isnt an airplane in the world with such metalsmithing cobbling.They arent built like aircraft,as it is told.
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