2021 Grand Design Solitude

I am filing a complaint regarding the frame manufactured by Lippert Components on my 2021 Grand Design Solitude 380FL (VIN [XXX] ). Lippert is the OEM supplier of the frame and has been directly involved in inspection and repair of ongoing structural failures. The unit has experienced repeated structural failures, including frame flex, broken welds, cracking of the main I-beam rails above both axles, torn steel upper sill plates and suspension failures. These issues began within the manufacturer’s warranty period and required extensive factory repairs from December 2024 to February 2025, including reinforcement of the upper deck, weld repairs, sill plate replacement, and added gussets. Despite these repairs, new failures developed shortly after. In September 2025, a Lippert technician (dispatched at Grand Design’s request) identified new frame cracks above both axles, a bent outrigger support, and repeated suspension failure. These were not pre-existing conditions but occurred after factory structural repairs. In December 2025, Lippert performed additional field repairs, including welding the cracked frame, adding fishplates, reinforcing outriggers, and installing cross-members. These repairs were performed under engineering direction, and Lippert confirmed no standard TSB applied to this condition. Despite multiple repair attempts, the unit continues to exhibit structural-related issues, including cargo doors opening during transit and recurring suspension failures. These conditions indicate ongoing and unsafe frame deflection and instability. Grand Design has now stated their repairs are done per a customer satisfaction campaign, and attributed responsibility for any ongoing frame issues to Lippert, and has abandoned any further assistance with cargo doors opening during transit. This represents a systemic structural defect affecting safety, including risk of debris or components entering roadways and loss of structural integrity during travel. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION

We are having issues with the frame flex failing, screws popping out from around the slides and also around the wheel wells. Seams on the exterior are pulling apart, roof is pulling away in several spots. The slides are pulling in crooked, external compartment doors open while traveling down the highway. Sawdust is noted in multiple spots in the interior of camper. We had the springs fall apart ( they literally fell off onto the highway!) and caused the axle to shift forward while driving down the interstate. Our camper was going sideways down the highway and caused a flat tire and left us stranded on the side of the highway. Thankfully we didn’t not hit any other vehicles. There is also a burning smell in the camper, the generator turns on and off randomly by itself.

I noticed wall movement against installed cabinets in the front of the RV. Movement was indicated by the shaving of the wall material leaving "sawdust" all over the front RV bedroom area. Upon inspection half of the required lag bolts were installed and those installed were too small for the pre-drill holes. Frame inspection by a dealer indentified split side wall support rails on both sides of the RV. My inspection also found bent outriggers which has allowed both side of the RV floor to sag down on the outside of the camper.

On multiple occasions during travel, We have had cargo doors and the main entry door open when going down the road. We have been fortunate that we have noticed the door flying open, to where we can quickly stop before losing any cargo. Because these are cargo doors, we carry cargo in these compartments. When the door flies open, there is a huge risk of cargo flying out of the vehicle and creating a hazard for oncoming motorists (flying through the air or upon the roadway). We have adjusted the latches on these doors to no avail. we get them to where they work and hold fine, then will start coming open again. We believe based on other evidence (missing sidewall lag bolts, loose sidewall lag bolts, bent sidewall lag bolts, popping sounds when raising or lowering unit, broken slide mechanisms, excessive sawdust on the inside of the vehicle, doors on internal cabinets unable to be opened due to interference, millwork trim falling off) that there is a frame failure or suspension issue with this vehicle causing excessive flex. These issues pose a life safety risk to any person traveling on a roadway.