NHTSA Complaint #11097125 — 2017 THOR MOTOR COACH CHALLENGER

ON 04/16/2018AT APPROXIMATELY 1:15 WHILE TRAVELING WEST ON I-40 MIDWAY BETWEEN MILE MARKER238AND236I HEARD A LOUD NOISE FROM THE LEFT SIDE OF THE COACH. I IMMEDIATELY LOOKED IN THE LEFT HAND MIRROR, AND SAW WHAT I THOUGHT WAS THE BATTERY COMPARTMENT DOOR, OPEN, FLAPPING IN THE BREEZE. I WAS APPROCHING EXIT236, SO I EXITED AND LOCATED A HOME DEPOT PARKING LOT JUST OFF THE EXIT. I PULLED INTO THE HOME DEPOT PARKING LOT AND UPON CHECKING THE BATTERY COMPARTMENT DOOR, FOUND THAT THE DOOR WAS SECURED. WHAT I SAW WAS IN FACT, THE BATTERY COMPARTMENT DOOR SKIN. I OBSERVED THAT THE DOOR SKIN HAD SEPARATED FROM THE FRAME. UPON FURTHER INSPECTION, NO MECHANICAL FASTENERS WE'RE LOCATED ON THE SKIN ,OR ON DOOR FRAME. I OBTAINED STAINLESS STEEL SELF DRILLING SHEET METAL SCREWS, FOLDED THE SKIN BACK INTO POSITION, AND SECURED IN PLACE WITH THE SCREWS, AND CONTINUED TO OUR DESTINATION WITHOUT FUTHER INCIDENT. CHECKED, AND FOUND NO OTHER DOORS AFFECTED. UPON RETURN TO THE DEALERSHIP, APPROX 1 WEEK LATER, I CHECKED ALL DOORS, AND FOUND THE WATER TANK COMPARTMENT DOOR SKIN TO BE LOOSE, ALONG THE TOP OF THE LEADING EGDE. THIS DOOR WAS REMOVED, AND REATTACHED BY THE DEALERSHIP. I CONTACTED THOR MOTORCOACH, ABOUT THIS POTENTIALLY SERIOUS MANUFACTURING DEFECT, AND WAS TOLD TO CONTACT MISHAWAKA SHEET METAL, MANUFACTURERS OF THE DOORS IN QUESTION. I EMAILED MISHAWAKA SHEET METAL ON 05/02/17 AND RECEIVED A EMAIL FROM THEM ON 05/16/17 STATING THEY WERE AWARE OF PROBLEMS WITH SOME DOORS, AFTER BEING ASSEMBLED USING A BAD BATCH OF GLUE, WHICH CAUSES PROBLEMS AFTER AN EXTENDED PERIOD OF TIME. I HAVE ATTEMPTED TO CONTACT THOR MOTORCOACH WITH THIS INFORMATION, WHICH APPARENTLY, THEY WERE AWARE OF, AS THERE HAVE BEEN A FEW REPAIRED UNDER WARRANTY. THERE ARE AT LEAST 8 OTHER OWNERS WITH COACHES EFFECTED. SHOULD THESE PANELS DETACH, IT COULD BE DEADLY !