NHTSA Complaint #11556235 — 2020 FOREST RIVER GEORGETOWN

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.