So on my 2019 Thor ACE 30.2 we have the Carefree "Longitude" power awning. We've literally only had the awning out twice - never on a windy day.
Before leaving on our most recent trip, I noticed a gap between the right awning arm & the coach body. Moving the awning out for a better look, I see that the top two self-drilling lag bolts (14x1) used have pulled out of the coach body and the awning is near falling away from the body altogether (bottom two bolts still holding). The top bolt appears to be in an aluminum channel, the second from top appears to be in just wood or nothing at all other than the exterior fiberglass.
As a temporary fix, I managed to get a larger bolt (automotive body bolt 5/16-18 x 13/16) to bite in the top aluminum channel - same size bolt in the second from top would not bite. I used butyl tape to seal the holes - which didn't flatten out as much as I have liked - the factory used something that felt like Dicor
I contacted Thor to get guidance on a more permanent fix & got "use bigger bolts"
- they mentioned a backer, but I see nothing of the sort present. Contacted Carefree for the same and got no response at all.
There's got to be a more appropriate fix for this situation. Seems my best bet is where I can bite into the wall of the aluminum channel in the top hole & try to get some wood in the second enough to get "some" bite. Then, go back with a caulk-based seal vs. the butyl tape to close the gap between the rail & the coach body.
Anyone else with experience on this problem or have "fix" advice?