Pilotadam
Well-Known Member
Lifetime Member
Just thought I would share a experience I have had with my 2008 Keystone Fuzion Toyhauler. 2 years ago I found the hinges on the Rear ramp door to have cut through the Fiberglass outer skin. Upon further investigation I found the rear ramp to be "soft" all long the Hinge area at the bottom of the door. Then when loading my SxS I notice the door flexing. At this point I started to investigate why, come to find out the Ramp is made up of plywood and foam. No metal at all! I went to my local RV repair shop and inquired about a repair or replacement method. They informed my they only thing that can be done at this point was replace the door. They called Keystone and was told a new Ramp Door would be $4,200 plus shipping. I thought no way I was spending that kind of money. I would rather make my own door.
So I removed the door and designed my own replacement out of steel box tubing along with plywood and insulation foam. When I disassembled the orignal door I found that they did not provied a way for water to drain out of the door if any enter it. And at the top of the camper they had install screws through the aluminum channel that allowed water to enter the door over the 10 year the camper has been outside. On the door I made I allowed a 1/2" air gap between the Aluminum channel and the plywood decking. Plus I drilled some drain hole to allow any water to get in to drain out. But the biggest change I added was a Aluminum rain deflector along the top of the door to prevent water from actual draining on to the top seal. I would recommend anyone who has a toyhauler to add some kind of rain deflector to prevent the water from getting to the top of the door when in the closed position.
Please review the picture I have added and let me know if you have any questions. After my door rotted I found many forums online were others have had similar problems.
Just thought I would try to save someone else from going thought all this work and expense. I ended up spending about $1,000 in material to make a new door including the fiberglass skin so it would match the rest of the camper.
So I removed the door and designed my own replacement out of steel box tubing along with plywood and insulation foam. When I disassembled the orignal door I found that they did not provied a way for water to drain out of the door if any enter it. And at the top of the camper they had install screws through the aluminum channel that allowed water to enter the door over the 10 year the camper has been outside. On the door I made I allowed a 1/2" air gap between the Aluminum channel and the plywood decking. Plus I drilled some drain hole to allow any water to get in to drain out. But the biggest change I added was a Aluminum rain deflector along the top of the door to prevent water from actual draining on to the top seal. I would recommend anyone who has a toyhauler to add some kind of rain deflector to prevent the water from getting to the top of the door when in the closed position.
Please review the picture I have added and let me know if you have any questions. After my door rotted I found many forums online were others have had similar problems.
Just thought I would try to save someone else from going thought all this work and expense. I ended up spending about $1,000 in material to make a new door including the fiberglass skin so it would match the rest of the camper.
