Ok so there are many Toy Haulers with Lippert Component door that have failed. I have a 2010 Road Warrior and the door has been failing for past couple years. Long story short, the door had no sealant around the exterior of Aluminum trim and water has infiltrated and caused the damage. SO before my Harley tires fell through it, I replaced it. Lippert charges $2000 for the door and $700-$800 for shipping.
So the new door did not align up with old holes so all 12 had to be re-drilled and tapped. Whom ever installed the original door just sat it in the opening and mounted it, which caused premature rusting to lower frame. I shimmed it 1/2" on the bottom and installed it so the gasket would seal. The new door came with hinges and springs. NO gasket, old handles get reused. The new door now does have silicone around the exterior aluminum but is already pulling loose from exterior fiberglass. I will replace this with an better RV UV sealant. The original gasket was installed in 4 pieces allowing water to seep between corner gaps. I purchased new D rubber seal and with the help of You tube found out how to miter corners for a continuous seal , so the new gasket is once continuous piece 32 feet around the perimeter of door.
These doors are just an Igloo cooler with some aluminum trim. There has been no changes to the design and construction of these doors. As you can see from photos the door is just two pieces of 1/8" plywood with Styrofoam sandwiched between it. There is no added wood where the hinges are attached.
I started seeing the bolts that go thru the door rusting and de-lamination on exterior of door. Once this is visible it is beyond saving. I will now, never leave the door down to get wet and plan to keep the exterior always sealed around the aluminum and plan to seal the interior as well. If you can keep water out I think you will get many years of use.
I cut up the door into 4 pieces and plan to use them as a ramp for our 16 yr old dog to get in and out of trailer..
I forgot to take photos of new door and seal, I can do this if someone wants to see it..
So the new door did not align up with old holes so all 12 had to be re-drilled and tapped. Whom ever installed the original door just sat it in the opening and mounted it, which caused premature rusting to lower frame. I shimmed it 1/2" on the bottom and installed it so the gasket would seal. The new door came with hinges and springs. NO gasket, old handles get reused. The new door now does have silicone around the exterior aluminum but is already pulling loose from exterior fiberglass. I will replace this with an better RV UV sealant. The original gasket was installed in 4 pieces allowing water to seep between corner gaps. I purchased new D rubber seal and with the help of You tube found out how to miter corners for a continuous seal , so the new gasket is once continuous piece 32 feet around the perimeter of door.
These doors are just an Igloo cooler with some aluminum trim. There has been no changes to the design and construction of these doors. As you can see from photos the door is just two pieces of 1/8" plywood with Styrofoam sandwiched between it. There is no added wood where the hinges are attached.
I started seeing the bolts that go thru the door rusting and de-lamination on exterior of door. Once this is visible it is beyond saving. I will now, never leave the door down to get wet and plan to keep the exterior always sealed around the aluminum and plan to seal the interior as well. If you can keep water out I think you will get many years of use.
I cut up the door into 4 pieces and plan to use them as a ramp for our 16 yr old dog to get in and out of trailer..
I forgot to take photos of new door and seal, I can do this if someone wants to see it..
