2020 Forest River Georgetown

While driving down [XXX] in Denver the front welds holding the propane tank broke. This left the propane tank at an angle only supported by the rear welds. Was fortunate that another RVer flagged us over and we were able to get off the highway and used a ratchet strap to support it so we were able to drive to get the bracket welded back into place. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

While a mobile welder was repairing the cracked rear bracket holding the ASME propane tank (NHTSA complaint #11555667) he repaired another full-depth crack, this one on the actual ASME propane tank mounting flange itself. This flange is welded to the tank by the tank manufacturer. This cracked tank flange is bolted directly to the cracked rear angled mounting bracket reported on Nov. 17, 2023. The tank mounting flange crack was close to an inch long and cracked at a gusset on the rear, outer mount of the tank ("outer" means nearest the propane compartment door). Please see the top and bottom pics. This second crack had rust in it on the top but was only partially rusted on the bottom, as if the crack may still be progressing. See the black spot on the compartment close-up pic. (I did not have any white paint to cover the welded area.) From previous pics I have this second crack is at least six months old and probably older. I just never really noticed it. One way this gusset-reinforced flange could crack is if the metal was repeatedly flexed at the end of the gusset, which is where it cracked. Interestingly, BOTH of these cracks occurred at the rear outer, just 2.5 inches from each other. The motorhome propane tank mounting structure has a unique support design in that only three of the four "corners" are supported by other structure. Normally a horizontal frame member supporting a lot of weight (up to 200 lbs total in this case) has a support at each end to eliminate flexing. The rear horizontal frame in fact is supported on each end by a vertical piece of square steel tubing that is welded to other structure. See the pic. The FRONT of the ASME tank mount has a similar horizontal run of square steel tubing. On the inner section of the welded bracket there is a 45-degree angle iron support welded to steel frame. See the pic. BUT the outer end of the front horizontal steel frame is NOT supported in any way; it's just sticking out. See the pic.

Another owner of a 2020 Forest River Georgetown GT5 model 34H5 just posted a pic of a crack at the 90-degree bend in the rear propane tank mounting bracket. This is an ASME tank that can contain 19.5 actual gallons of propane. Previous ASME propane tank mounting bracket cracks reported by owners of Georgetowns were all on the front propane tank mounting bracket and were broken welds that allowed one end of the propane tank to drop almost to the road while driving. They were NOT a crack at the 90-degree bend in the bracket and also NOT on the rear bracket. I just cut three tie wraps to expose that bend on our 2020 Georgetown GT5 34H5 and my rear propane tank mounting bracket is cracked in exactly the same place. The crack is full depth at the exposed end of the bend. The crack appears to extend 2" to 3" through the bend of the 8" long bracket. There is some rust in the crack at the end so the crack started a while ago. A total failure of the bracket would allow one end or both ends of the ASME tank to fall and strike the ground. That could be like a bomb exploding when driving, the same as the previously reported front ASME tank bracket failures could cause. Our motorhome is four years old with about 17,000 miles. It was built in May 2019.

Windshield developed a stress crack starting at the bottom-center, and is growing vertically. Several other owners have reported the same issue, originating in the same exact spot. Some have reported that the original windshield was too large and, consequently, did not leave sufficient room for caulking at the bottom. Others have reported that a defect in the vehicle's dash causes it to press against the windshield. This has been reported to the factory by numerous other owners, and the factory refuses to correct the issue.