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Old 06-30-2020, 05:08 AM   #1
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Brand: Thor Motor Coach
Model: 31L
State: Texas
Posts: 44
THOR #19181
And so the repairs have begun...

It is fortunate that I had done a lot of reading before we picked up our 2013 Four Winds. I already knew that much of the 'fit and finish' at the factory was of poor quality, and had mentally prepared to just fix what needed fixing. I also read the horror stories from new owners dealing with factory warranty repairs. So a used model seemed to be a nice middle ground between a new unit we would feel compelled to repair via warranty and a really old model that would need major work.

As it turns out, owning an RV, especially living in one full-time, is a great way to become a semi-expert in many different fields! So far I've done the following:
  1. Replaced tail lights on the right side, which failed due to corrosion caused by a water leak at the top of the lens. Wood rot below does not seem extensive. I just sealed it back up w/ butyl tape.
  2. Repaired, replaced and/or adjusted several drawer and door catches, latches and guides.
  3. Replaced the air vent hose on the fresh water tank. It was blocked with what appeared to be insect nests, maybe mud dobber or something similar?
  4. Sanitized the water system/lines.
  5. Crimped a couple of DC fuse holders
  6. Fixed a couple of small holes in the fiberglass curve right behind the rear roof joint

The small holes (which I covered with Dicor non-leveling) might have been caused when I attempted to snap a covering panel back into place. It coveres the wiring going to the rear lights. It is a fine example of Thor factory workmanship. Super-thin nails with no heads jammed in at many angles, many not finding purchase in anything solid. I am re-attaching the top trim piece to the main styrofoam board w/ finish nails. No more nails into the roof (not enough roof edge left there). I re-glued the bottom trim piece. I will hold it all in place w/ 5 screws into the foam core walls. It won't fall out again.

Many parts are on order to repair the rear view camera (broken antenna) and replace dead batteries (cab remote, radio remote) and convert all lighting to LED. Then install a basic solar system.

To do:

- fix a couple of window blinds
- replace missing valve extenders on right rear
- remove hitch tongue when I figure out how to remove the receiver hitch w/out a key
- replace spare tire holder
- bypass air vent diverter vacuum canister
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Old 10-11-2020, 08:59 PM   #2
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Brand: Thor Motor Coach
Model: 31L
State: Texas
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THOR #19181
Completed more repairs:

- blinds fixed
- had Discount Tire replace the valve extenders with some I picked up at O'Reillys - they ended up having to replace the actual valve stems in the process, then aired all the tires up FOR FREE - these people!
- decided to just do without the spare tire. When it almost fell off, we just threw it into the back of the CR-V.

On a related note, anyone want a standard size Class C wheel w/ an unused tire? Make me an offer. Will be in Texas through the end of the year.
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Old 10-11-2020, 09:06 PM   #3
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Glad to see that you keep making good progress!
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Old 10-11-2020, 09:12 PM   #4
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THOR #19181
Progress, yes, and yet ...

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Old 10-11-2020, 09:18 PM   #5
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Please don't forget that every thousand mile journey begins with just single step...
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Old 10-11-2020, 10:59 PM   #6
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Quote:
Originally Posted by donblanco View Post
Progress, yes, and yet ...

I gotta commend you on being that organized. After each trip, my punch list is on scraps of paper..............several scraps.
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Old 10-11-2020, 11:12 PM   #7
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State: Texas
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THOR #19181
Quote:
Originally Posted by Bob Denman View Post
Please don't forget that every thousand mile journey begins with just single step...
Have you been reading our travel blog?

https://vagabondians.com/the-journey...a-single-step/

That's from over a decade ago - wow, I feel old...
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Old 10-11-2020, 11:19 PM   #8
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I knew I heard it somewhere...
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Old 10-12-2020, 02:09 PM   #9
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I got my 2018 Chateau 31E new about 3 years ago. Here is a list of stuff I've fixed (or had fixed under warranty).

- Expanding foam crumbled in left side stowage compartment
o Applied new expanding foam and painted black
· Trim at front of slide was loose when new
o Glued/sealed with silicone adhesive
· Bottom of drawers popped out in kitchen and bedroom
o Fixed 2 drawers with glue and staples
· Hinges ripped out for stowage under bed
o Installed new screws
· Mud flaps in front of rear tires – supports ripped out.
o Used zip ties to secure flaps
o Installed screws and covered with gorilla tape
· Water leaking inside from under slide
o Tightened fitting on water heater
· Compartment doors over sofa come open while driving
o Installed magnetic latches
· Weatherstripping in stowage compartment by entry door came out, leaving gaps to outside.
o Re-installed weatherstripping and sealed with gorilla tape
o Gorilla tape came off, so sealed it with Flex Seal
· Auto leveling jacks failed with a “low voltage” error
o Repaired by fixing battery grounds
· Metal bar came off front right window blind
o Blind replaced under warranty
· Kitchen window blind would not stay closed
o Blind replaced under warranty
· Generator wiring conduit melted on generator exhaust pipe
o Wrapped housing with friction tape and secured to frame using zip ties
o Conduit was replaced during later generator repair
· Generator cranks but will not start
o Had ignition coil and control module replaced under warranty
o Also replaced melted conduit
· Track for bedroom sliding door ripped out of overhead
o Secured with new screws and additional screws
· Trim over front of dinette bench lifted
o Glued down with Titebond
· Rear bedroom window valence/shade fell off
o Re-attached with larger screws
· Intermittent propane smell
o Camping World found a leak at regulator and repaired it
· Coach wing walls delaminated underneath coach
o Wing walls replaced under warranty (Oct 2018)
· Slide stops half-way while retracting (intermittently)
o Re-synced motors, but still happens occasionally (Oct 2018)
o Camping World did adjustment (Dec 2018), working okay for now
· Fuse for bedroom, hallway, and kitchen light keeps blowing (Oct 2018)
o Camping World repaired electrical short (Jan 2019)
· Light under awning not working (noticed after wing wall replacement) (Oct 2018)
o Camping World replaced LED light strip (Jan 2019)
· Interior decorative trim fell off upper right of slideout
o Re-glued it (Oct 2018)
· Rear window blind will not stay down
o Received replacement from Thor and installed it (Nov 2018)
· Kitchen window blind will not stay down (2nd time) (Nov 2018)
· All propane stopped working (Nov 2018)
o Replaced regulator with an MB Sturgis regulator
o Discovered holes in hose to grill connection – probably chewed by squirrels
o Replaced hose and installed squirrel guard on portion of hose inside wheel well
· Battery hold-down straps broke (Dec 2018)
o Replaced straps with new ones, which broke after one trip
o Replaced them with Atwood straps (Jan 2019)
· Battery disconnect switch not working (Jan 2019)
o Replaced relay assembly
· Cannot insert key into entry door lock (Jan 2019)
o Installed new entry door latch/lock (April 2019)
· Left front tire had excessive inner tread wear (June 2019)
o Got alignment done at Rice Tire, Frederick
o Replaced tire with new Hankook Dynapro HT
· Wood panel at side of front dinette bench fell off (Aug 2019)
o Installed bolts to re-secure it (was just screws into particle board)
· Inside rear tire driver’s side went flat. This also caused excessive wear on outer tire. (Aug 2019)
o Replaced inside rear tire as an emergency repair during trip (Cooper Discoverer HT3)
o Replaced outer tire later at home (Hankook Dynapro HT)
· Inside right rear tire blew out (Oct 2019)
o Emergency repaired with a Sailun Terramax tire
· Slideout would not extend (May 2020)
o Both slideout motors were replaced
· Fridge will not operate on AC power (green light gives 3 flashes) (June 2020)
o Replaced AC heater element
· Rear bedroom vent fan will not turn on (June 2020)
o Replaced circuit board
· Generator exhaust hanger came off
o Reattached to RV using larger screw, and tightened exhaust clamp at muffler
· Check engine light (July 2020). Codes for Bank 1 Catalyst Below Threshold and Evaporative Control System Leak.
o Century Ford replaced purge valve and an elbow fitting that was chewed by a squirrel.
o However, check engine light came back on 2 days later with same codes.
o Catalytic converter and an O2 sensor were replaced August 2020.
· Main stowage compartment floor rotted & delaminated (Aug 2020).
o Replaced with new exterior grade plywood, new vinyl flooring, and sealed with weatherstripping, expanding foam, and caulk.
· Outer right rear tire had a blowout. Sept. 2020, `48,000 miles
o Replaced both rear right tires
· Cabinet door over fridge fell apart
o Glued it back together


I've also done several upgrades:


· Installed shampoo/soap dispenser in shower
· Replaced shower nozzle with Oxygenics nozzle
· Added ventilated memory foam mattress topper to overhead bunk
· Built inside step cover board to provide more floor space
· Installed cabinet door magnetic latches in cabinets over sofa since they were opening during travel
· Built cover for stove to provide more counter space
· Installed Hellwig front and rear swaybars
· Installed Saf-T-Plus steering controller
· Replaced Axxera radio with Pioneer AVIC-8200NEX Nav/DVD/CD receiver
· Sealed inside taillight openings using spray-on rubber coating (Rustoleum equivalent to clear Flex Seal)
· Added Dynamat Hoodliner sound/heat insulation to inside of doghouse (interior engine cover)
· Replaced analog thermostat with Coleman digital thermostat
· Installed Bilstein HD shocks
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Old 10-12-2020, 02:21 PM   #10
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Model: Tiffin Wayfarer 24 BW
State: New York
Posts: 16,865
THOR #8860
Wow! RVing has certainly kept you busy.
How is your rig performing now?
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Old 10-12-2020, 02:35 PM   #11
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Originally Posted by Bob Denman View Post
Wow! RVing has certainly kept you busy.
How is your rig performing now?

It's performing great. With the handling upgrades and sound isolation and stereo upgrade it's a lot nicer to drive than when it was new. I try to keep it as nice as possible, and I'm very anal about maintenance. So other than some minor cosmetic wear and tear it is actually better than new.



I still have a list of upgrades I'd like to do. More sound deadening, perhaps solar and inverter. Since I've had multiple rear tire failures my priority is to replace the tires with commercial C-type tires. The tires are all pretty new right now, but I will probably replace them soon, and definitely before next summer.
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Old 10-12-2020, 02:42 PM   #12
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😁 The lists just get longer and longer...👍
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Old 10-15-2020, 10:58 PM   #13
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Model: 31L
State: Texas
Posts: 44
THOR #19181
Today we ordered many things and bought many more things at various stores. Almost finished ripping the carpet out of the bedroom. I think there was enough sand in it to stock a terrarium! Previous owners must have been beach lovers.

Good news, there is linoleum underneath. Once I clean up the edges then I can add a few strips of quarter round, mop it down good and toss a few runners in there and it will be much nicer.

Also bought clean & wax solution so I have *that* to look forward to. Good thing we also bought the extendable ladder.

We also bought soft-closing drawer guides to test out on a few of our many malfunctioning drawers. Maybe the next time we drive we won't need to bungee cord all the drawers shut!

Hopefully I can finish all that in a week, before the Amazon orders start rolling in. One vent screen, one VortexII fan, and a set of miracle probes for the black tank.

By the time we get to Livingston, I may nap for the entire six weeks!

Wife has scuffed all the kitchen cabinets and is masking off everything in preparation for painting. I hope I can get her to take a break long enough to make dinner.
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Old 10-15-2020, 11:46 PM   #14
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Have her put dinner together in the RV.
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Old 10-16-2020, 02:23 PM   #15
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THOR #19181
Quote:
Originally Posted by Bob Denman View Post
Have her put dinner together in the RV.
As that is where we live, where *else* would she do it?
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Old 10-16-2020, 02:34 PM   #16
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Model: Tiffin Wayfarer 24 BW
State: New York
Posts: 16,865
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Old 10-22-2020, 08:52 PM   #17
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THOR #19181
was doing so good until I tried replacing the kitchen faucet. Now I'm contemplating which tool will be the first to be thrown through a window...


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Old 10-23-2020, 12:05 AM   #18
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Originally Posted by donblanco View Post
was doing so good until I tried replacing the kitchen faucet. Now I'm contemplating which tool will be the first to be thrown through a window...




What’s the problem with replacing the faucet? I just did mine and while there were a couple of surprises it was a pretty straight forward upgrade.
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Old 10-23-2020, 12:20 AM   #19
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What’s the problem with replacing the faucet? I just did mine and while there were a couple of surprises it was a pretty straight forward upgrade.
2/3 wall from floor to back of sink. Can reach water lines with one hand only.
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Old 11-02-2020, 12:27 AM   #20
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2/3 wall from floor to back of sink. Can reach water lines with one hand only.

Finally pulled staples and partially cut out the wall/panel so I could actually reach the pex/faucet connections. Was able to vice grip things tight enough that I think I finally stopped the leaks. Crap on the shelf holds the panel in place in the meantime.
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