Thor Forums

[TurnerFam]

the factory service center replaced ours early last year, the main bay and the wet bay floors - they were swelling in places, delaminating, etc. The issue is, as I explained to them, if you build a 'box' that has no way for drips, spills, or rain intrusion to escape(especially for the wetbay!), you MUST build it so that it is absolutely, positively, water TIGHT!

but, they don't.

Thor builds these coaches with 'box' compartments, built by humans, and screwed and glued together. The surface material is a good white 'water resistant/formica' type product, BUT, it is applied to a plywood base. Plywood does not do well in wet environments or when subjected to water for even a short period. The white covering looks good, and provides better 'lighting' in the bays, but unfortunately is not installed on the plywood base properly.

The factory lays out plywood sheets, then adds the covering with glue. They then CUT the pieces to the right sizes, with each piece having four RAW edges, for the building of the 'boxes', where they screw them together and add a silicone or similar sealant in all the corners.

Even though you are putting the pieces against each other, screwing, and adding sealant, water that sits in a box WILL eventually find it's way into the raw edges! This is the true problem and can only by solved one way, if this type of manufacturing of 'boxes' is to continue: WRAP each piece of plywood FULLY with the water resistant covering BEFORE piecing together the boxes.

as I've confirmed again this week, with several inches of rain during traveling for several days, our bays CONTINUE to have water/rain infiltration. While I've taken many steps to seal, foam, etc., nothing helps, and I can't for the life of me find HOW the water is coming in!
Thor is not doing a job, not even a poor job, of making sure that these bays keep water out.