When to Crossroads and met with the Lippert rep. They had removed the bottom skin and the front cap. There are no broken welds, all the welds looked good and could see no physical damage. Once that was all removed and the trailer was lifted you could see where the frame was flexing. This is not some lightweight frame, the walls are 4 gauge steel making the walls of the frame tubes about 1/4" thick and from what I was told is heavier then most manufacturers use. The side walls bolt to the frame in two places behind the rear pin box crossmembers. The walls do not attach in front of this crossmember because of the frame design is not a box but an angled or notched design so there is nothing to bolt to. The frame flex starts just about where the forward most sidewall bolt is. Front of the trailer is on the left on the above picture.
The frame is designed like this because the front cap is curved or rounded so a square front frame would not work. As you can see from the above picture there is about 9" of wall in front of the frame rail. To reduce the flex they are going to extend the frame rails as far forward as possible and then run a new crossmember to the pin box area plus add a couple extra braces and gussets between the new framing and existing framing. The side wall will then be bolted to this new framing. I should get the rig back late next week.
