Hi werkerb - We have a 2020 39FBB and had similar issues on the camp side of our unit. It was just below where the front cap and vanity slide meet. I had it repaired in Tishomingo under warranty a couple of years ago.
There’s some good info about that in this thread that you might find useful.
I also replied to your Facebook post in the Vanleigh group there. Did I understand it correctly that your insurance is denying it and calling it structural failure, but Lippert won’t cover it either? That’s a tough spot they’re leaving you in, maybe Tish or Affinity can advise you on repair options. Also, where are you located now?
In your video the movement you are seeing is the walls separated from the frame and why the bolts that go into the wall from the frame are sheared. The angle iron that is tack welded to the steel tube of the frame and supports the wall has broken loose. The holes you are seeing are the tack welds broken free. This is happens often along with the typical flex issues.
My angle iron was also broke and had to be welded back. That angle iron is often missed in flex repairs and the wall is reinforced and the angle not secured causing the issue to occur again. That piece can take a new weld with the filon removed like you have it but the uncertainty would be additional breaks within the wall.
I know a Vanleigh owner that went through 5 repairs and on the 6th his insurance totaled the RV. There are several posts about flex in this forum in addition I have a video where we outlined our repair.
You had it corrected at Affinity? Did you contact them or speak with Rod? When did you have the repair?
Tiffin has been extremely helpful in helping folks get the flex issues corrected even covering them outside of warranty. They aren’t always as helpful if they have paid to have the repair at a different facility and it breaks again. However, I have a Vanleigh friend that was there last week after having his unit repaired at another facility and Tiffin covered the second repair. If it is the angle iron as it appears in your video Lippert typically refers to the manufacture of the unit.
Correct we did have the second frame flex done at Affinity in Dec 23. They repaired the aluminum frame of the wall.
The current issue is related to the middle frame tube on the passenger (off door) side is actually broke in two places where the holes are at. I can actually move that piece by hand when the rig is not on the truck. I didn’t try it with the kingpin up but when it is on the truck that is when it comes down as in the video and slides down when it is off the truck. That is how I figured out it could be moved. I did not see any angle iron but was not looking for it either.
When the angle iron on the outside of the middle tube breaks that is usually associated with the flex symptoms and why I suggested contacting Affinity again.
After reading your last comment and going back and looking at your pics / video I think I am seeing what you are referencing. I am not positive about the frame on a FBB but I have not seen any Vanleigh frames that have three curbside tubes - not even the heaviest unit produced being the Ambition. If looking from under the unit what you are likely seeing is the outer angle iron that supports the wall, the middle tube and then the inner support all sandwiched together. Does that seem correct?
The pictures below are pictures from a 320/34RLB frame demonstrating what I am talking about. The first picture is looking down showing that inner support (for perspective you can see the pinbox in the top right corner of the pic). The second picture is the curbside of the frame showing the tube and the angle that supports the wall.
In looking at your pics does it seem that inner support (top pic) welds have broken and you are seeing the holes into the tube which appears to be the middle tube?
This picture is what made me go down the typical flex direction. The long metal piece that I squared in your pic is attached to the angle iron and tube to provide spacing / protection between the screw heads that go up into the wall structure and protect the Filon wrap below.
