Can we re-visit the Sundowner rust issue? I dropped my 2006 Sundowner 777 trailer off at the Sundowner dealer after finding rust under the floor mat, they said I need a whole new floor. Its still under warranty which is a good thing I guess, but Im wondering for those of you who have already been this route with your trailers, how do they fix the issue? and whats to prevent it from happening again a few years down the road? Does Sundowner guarantee this repair or extend the warranty or should I just trade the darn thing in and forget about it? Anyone here a few years post having to deal with this, and if so how did your trailer hold up and how did you deal with the Sundowner place? Im not sure what I should be asking for/demanding or what to look for in a repair job. Anyone??? 
My understanding is that since the replacement floor will not have the coating that caused the corrosion problem, it should have a normal trailer floor life.
We have two Sundowner trailers with replacement floors done at no cost by Sundowner several years ago. We are completely happy with them so far. I don’t think Sundowner extends the warranty. My trailer is 10 years old and my daughter’s trailer is 7 years old. I love my Sundowner. It is the easiest trailer I have ever owned, and has needed minimal upkeep. My previous trailers, a steel Valley and a Colin Arndt, needed constant maintenance.
Thanks, good to know!
Anyone else??
they replaced most of my floor for free. Probably 2 years ago. no probelms so far. mine gets used 3-4 times per week about 45 weeks of the year, and peed in a lot.
mine goes in for annual maintenance next week. I always pull the mats and hose it out well before it goes in so we both can easily see every inch of the floor.
It is my understanding there was a bad coating on the floors that were rusting out so once they replace with one that does not have the bad coating you should expect normal floor life.
There is a long thread on this issue!
The floor issue is triggered by the frame, more so than their “suncoat” crap that was sprayed on it.
There is a long, detailed thread on it, I won’t repeat all the details.
In a nutshell, Sundowner used cheap steel on their late 90’s through late 08 models. (Probably like the Toyota frame issue, except THEY did right by their customers) It was many layers rolled together to make a single layer. The powdercoating failed and the steel started rusting, sometimes badly. Those layers that were rolled together? They flaked apart, often to the point the frame would disintegrate right in front of you in big flakes.
The steel then was able to make contact with the aluminum floor. Two metals coming together produce a battery effect and the aluminum starts to break down, or corrode (it’s not rust, BTW) The coating hides it, and you often don’t even know you have a problem until you strip the coating off.
(everyone who has one of these steel frames trailers, labeled either Valuelite or a numerical series ending in a 7 should strip the coating off and have it inspected for issues)
Get a warranty claim in ASAP. Expect that they will likely deny it, claiming it’s your fault. Fight it. I keep hearing talk of a lawsuit, but haven’t heard of anyone starting a class action…yet.
Check the other thread for more info. But remember this: just replacing the floor alone won’t fix the entire problem.
Good luck.
They will TRY and do a band-aid approach of sanding and recoating the frame/floor. DON’T fall for it because the rust that is flaking off is the steel that is no longer supporting your trailer floor…we forced them to replace the entire frame on ours because we had pretty much lost half the thickness of it due to rust. Our mechanic told us that we’d have no trailer left in a few years if they didn’t replace the frame. Of course, we had to threaten a lawsuit, etc. but they did eventually pay to have it done. Now we need to trade it in for something taller and let me tell you, the choices are narrow and EXPENSIVE!
I reckon we are screwed with this issue on a 2000 model? I went out and looked underneath it after seeing this thread…right fron corner of underneath frame is almost gone…
Glad I traded mine in this winter. I had my floor stripped of the coating but it always worried me. Won’t buy another one.
Mine was out of warranity and Sundowner would not help me a bit. Will never own another one.
Sundowner admitted to me the problem and said they would not help unless I bring the trailer there so they can fix it and than I pay for all repairs!!! Steve Chalk is the warranty manager. They will never get my business again.
