It has come to my attention that there is a serious design flaw in the powder-coated steel frames on the "Valuelite" models of Sundowner Trailers causing these frames to rust at an accelerated rate. Further, I understand that the manufacturer has not alerted the owners of these trailers to the damage occuring and the danger of a major frame failure.

In 1999 Sundowner began building "Valuelite" trailers using power coated steel frames.  There is an inherent design flaw in the engineering of this type of frame.  Powder coating does not flex with the trailer, and what happens over time, as the trailer travels and vibrates, the powder coating over the steel frame splits apart at the frame joints.  Moisture is then trapped between the frame and the powder coating, causing the steel to rust at an accelerated rate, as it has no way to dry out.

Sundowner is aware of the problem.  However, to my knowledge, I have never heard of any type of factory recall nor even any type of notice of concern being sent from the manufacturer to all affected customers.  It is reasonable to assume that almost every "Valuelite" trailer presently on the road has this problem, and that most owners are blissfully unaware of the problem.

The only solution I know of to "band-aid"  the problem is to have the entire frame sanded with a power sander, then a "metal cleaner" should be applied, then a "metal ready" product applied, and finally at least 3 coats of "POR 15" should be applied to stop further deterioration.   POR 15 will need to be applied every few years to insure full rust prevention.

If the trailer is still under warranty, Sundowner will do the work, although the trailer owner should make sure that all of the above procedures are done.  It is interesting to note that this winter Sundowner announced that they have stopped making Valuelite trailers without any explanation as to why they were discontinuing the model.

I hope this information is helpful to any owners of Sundowner "Valuelite" trailers.

Yes, the Valuelite is the same as the Sunlite. Although in an effort to disguise the steel-framed trailer, they changed the name to the Sunlite 727 or 777 series. There was a time when Sunlite meant the all-aluminum trailer.

It is interesting that even Sundowner dealers have a tough time keeping track of these subtle model name changes- when they replaced the 'Valulite' name thay started using the 'Suncoat' black finish on steel, basically like a bedliner material. This also has prven to be a warranty problem, as the same thing happens- the stuff will peel or flake, then water is trapped against the frame, causing premature rusting. Do you realize that the blackcoated sidewalls in the horse area is made of a thin layer of steel? Fact is, the coating doesn't adhere well to aluminum, and they spray the 'Suncoat' on rather than use rubber lined walls, which is more expensive(and provides some cushion for the walls when kicked).

Won't be long before this thread gets locked up.

Tick..........Tock..........Tick..........Tock............

Do you mean that Horsetrailerworld .com will squash this post because Sundowner is such a huge advertiser?

This is a good posting, with the discussion of facts.

Only when the chest thumping starts, along with the angry responses from Sundowner loyalists, will the thread degrade into rhetoric and be discarded.

This forum should include factual events about actual trailers and trucks. Only by knowing about any problems, can we repair, modify or avoid them. The more educated we are about what we own or plan to buy, the better our experience will be.

VAC isn't trash talking, he is relating one fact to the best of his knowledge. He deserves the same respect as someone with a lighting or tire problem.

VAC, Sundowner and Exiss threads have been extensively discussed in the past, if you care to do a search. Most of the members who have been here a while, are tired of the controversy which invariably occurs after a posting such as yours.

I for one, am thankful that you wished to share your information. I hope to hear more from you in the future about other topics.

BOL  Gard

As a 20 year Sundowner owner, I would say that the problem was recognized, hence the change in manufacturing procedures. Other brands offered the same style undercoating etc, wonder if they are changing as well? Change usually is brought on by necessity. All of us should take the time to inspect the undercarriage and frames of our trailers regardless of its makeup. As well as inspecting the flooring under the mats. It's like changing the oil in a car, regular maintenance. I do feel really bad for anyone that's caught in the middle with no factory warranty left. But it could happen to any manufacture. It's very unfortunite in any situation.

When was the flaw discovered and corrected?

The problem has never been corrected.  The most amazing thing to me is that Sundowner has never recalled any of these trailers or attempted to alert their customers of the inherent dangers cooncerning the frame issue.

So alerting my friend, who just bought a used 2005 Sunlite 727 would be a good thing. Otherwise, since she doesn't spend a lot of time on the internet, she would have no access to this information.

I think it is a nice thing that this topic (which you claim has been discussed many times) was brought up again. Many new people join this forum frequently and reposting information as valuable as this is a good thing for those people.

Using the search function allows the new members, to access a wealth of preposted information. This knowledge is voluminous and varied, incorporating almost any particular involved in the ownership of trucks and horse trailers.

However, constantly rehashing the same issues, is counter productive and makes it quite uncomfortable for all involved. It detracts from the camaraderie that the membership has enjoyed, and may result in some readers finding another venue in which to browse and source for information.

This thread was different, in that it was quite tempered in its manner when compared to past examples. Perhaps it means we are becoming more civilized, and can actually discuss an issue.

Discussion is always the best policy, but "Don't ask, don't tell" has been most recently used to avoid conflict. It is a self preservation tactic, and I have written about the results in my political correctness thread.

I'm hoping that this will be our new start in the discussion of facts with little rhetoric being involved.

BOL  gard

A lot would depend on where you live; snow belt or dry area.

Just as all aluminum trailers are not built equally, neither are all steel trailers. Some manufacturers will prepare the steel as well as possible, while lesser quality builders will cut corners. This is why it's best to be educated about the various brands when you shop, and know what the build quality and reputation is of the brands in which you are interested.

Gard

I do not write since I am not as gifted as others on projects.  This subject has caught my eye.  I am glad the information was brought up.  I don't have lots of people helping me and all the fixes I either have to do or pay someone to do for me.  My husband owns the truck but I have to do everything since he is not involved with horses.  So buying a new/used trailer is my business and the closest dealer is Sundowner.  I was thinking about trading or buying a different horse trailer.  Some information might be like "beating a dead horse" but I do not think this was one of those times.  As far as buying a used or new Sundowner I will be printing this information and showing my Sundowner dealer.  I am interested in learning about what they are going to do to help me not have this issue.  Especially if I want a used horse trailer.  Thank you for keeping me and my animals safe. 

Duckman, it is a problem only with Sundowners because of the powdercoating as VA points out. The other brands that are painted aren't showing this "rot" (the best word I can think to use).

(Edited for spelling, because I can't spell)

There are other brands of steel frame trailers with rust issues (oxidation) depending on where they are used

For those of you that are Sundowner Valuelite owners (or know people who are), and have any technical questions regarding your powder-coated frame rusting, I would suggest you call Anthony Holder, Sundowner's Warranty Manager.  His e-mail address is:  anthonyh@sundownertrailers.com.  He can be reached at 1-800-654-3879.

Best of luck.

Clay Smith

Mandy:

I am not sure when the problem first surfaced.  Through all of this I have met people who have had their frames treated as early as mid 2002 by Sundowner.  So obviously they knew about the problem then.  The only thing Sundowner did to correct the problem was to discontinue making the trailer this winter.  That's 9 years, and not tell anyone about it.

I'm fully aware of the search function as I have used it many times. Often because I can't get answers to questions I have by asking them.

The difference in this case is the information that was presented here would not ordinarily affect me. This also means this is information I would have never found by searching and especially not for this particular problem, but because it was mentioned, I found out about something I had never heard of, but that does also affect me since a friend just purchased a trailer which falls into this category and this is a friend I haul with quite frequently. Presenting her with this information could keep both of us from getting in a bind somewhere on the road.

I also read Gard's political correctness thread and I agree that there is way too much "don't ask, don't tell" stuff around here. I'm a member of several other forums and this one, as probably the smallest one I am a member of, seems to have the biggest problem with people getting their feathers ruffled over other peoples comments...and quite frankly the things here that I have seen people get their feathers ruffled over are rather simple things that, elsewhere, other people would have just blown off.

The strange thing is, most other places, things are disputed in a very civil manner (depending on which other forum I am on) and most of the time, many good points are stated from opposing sides, ending often with the "let's agree to disagree" comment. In just a short time here, I seem to come across more "my way (or my brand) is better and there is no other way (or brand)" and yet there seems to be little support for certain reasons.

I've rec'd PMs from members on several topics with opinions they were afraid to state publicly just to avoid controversy. This is sad because it takes away from the educational value of the board. Almost anytime someone has a question, you can bet there is someone else in the world with the same question, reluctant to ask. If we only share the "good" stuff via PM, there are many people missing out on valuable information.

We tried to send an email to the address you listed, but, it came back as incorrect, it could be they are getting hit with so many emails, it was bounced back.  Maybe they even changed it.  Have you had trouble sending emails to that address? 

Thanks for bringing this to everyone's attention.

TwoBucksRanch

Two Bucks Ranch:

Anthony Holder's correct e-mail address is: anthonyh@sundownertrailers.net.

Please excuse error.

Travel:

I believe the Travelblazer II is powder-coated.  Check underneath and/or call Sundowner.

Good luck.

You are exactly right. This was the first time I heard it. So Thank You. Although I will never own another one (not for this reason) I am glad you shared it with us. I just don't understand why sone people have to be so rude!

You are exactly right. This was the first time I heard it. So Thank You. Although I will never own another one (not for this reason) I am glad you shared it with us. I just don't understand why some people have to be so rude!

Sundowner dealer...I am not singling out Sundowner trailers.  They are nice trailers.  If ANY manufacturer had a structural problem, I would want to see them do the right thing and announce a public recall on the models affected.  Are trailers regulated like vehicles are, and product recalls for safety reasons made mandatory?  I don't think so.  Most of the trailer manufacturers I have dealt with have been very good about fixing problems, and I would expect Sundowner to be the same way with this problem.  Only time will tell.  No one manufacturer is perfect.

We take Sundowners on trade, and I am always amazed at the customers who insist their Valuelite or Sunlite is all aluminum, until we show them different. Are they not informed of this at the time of the sale? 

I don't have a problem with any brand of steel framed trailers at all, as long as they are priced according to what they are, and the customers know what they are getting up front.  That's one thing we do here...point out the differences in an all aluminum trailer vs steel framed trailer, and let the customer make the choice, but at least it's an informed decision, usually based on price.

LOL!!!!!!!!!

I emailed them also and got the EXACT same response as was posted above. I wonder if its something they have saved on their hard drive kinda like those "scripts" telemarketers have. LOL!!!

Here's what I got:

Sundowner would like to say " THANK YOU" as a Sundowner owner or
potential owner for taking the time to contact us about the information
you read and are concerned about.
Unfortunately everything you see on some web sites are just simply not
accurate at all, and this is certainly the case with this information.

We want to assure you that this product has always been and still is a
very good product. For the last several years it has carried a 3 year
hitch to bumper warranty ( excluding tires, brakes, bearings, accessory 
batteries and abuse) along with an 8 year structural warranty. This is
by far the strongest warranty in the industry. We stand behind our
products as we always have and will continue to do so.

Something to think about :   For the Sundowner Products to carry the
strongest warranty in the industry we have to have a lot of confidence
in that product with every aspect of that product being considered.
Today we still have the strongest warranty in the industry !

Thank you for your time

Of course, since many individuals here have stated they are having their's covered by warranty work, I am going to reply and question that as well.

I don't have a dog in this hunt but... This power coated, frame, rust, bubble thing, looks to me like it falls under the 3 year bumper to hitch warranty. If you are inside the 3 year window, then there may be some help available. It don't say they will warrant the frame's powercoat forever. (And is it really powercoat, Got to have a mighty big oven to bake that stuff on a 40+' trailer frame!!). If you are past your 3 years, then it seems to me you are on your own. I know it's sad to say, but it is, what it is... paint and power coat ain't structure, so the 8 year structure deal is out the window. If you got one of these trailers then you got one. I almost bought one back in 2001, had I done so I guess I would be fired up too, but it would have been out of warranty by now and it would be up to me to repair it, have it repaired or trade it off on something else.....

Sometimes I wish I still had my old 24', steel, Circle M stock trailer with the 4' dressing room. Kept it ten years, adjusted the brake every once in a while, repacked the bearing 3 times, and replaced the tires once...That's it.

I'm not taking sides on any of this, don't own a Sundowner, never have, but then again I may strike a wild hair and buy one before the week is out. Ya never know!!.

I'm on the outside looking in.......Here's the power coat process per...  http://en.wikipedia.org/wiki/Powder_coating

I either throw stones or play nice, depending on the response required for the circumstance.  I threw stones at you in my first post, not because of the Sundowner trailer problems, but because of your rude response to Abby & Cindy, who I happen to agree with. 

My second "be nice" post only concerned the trailers, and the fact that every manufacturer has their share of problems, and normally they are taken care of without too much incident.  I don't have any reason to throw stones at other trailer manufacturers because we sell them all, and they all have their place in the scheme of things.  If you are one of the Sundowner dealers who is an honest sales person, then I am humbled, and I apologize for suggesting that you might not mention the problems to your potential customers.   Back to work....I actually have a customer looking at a nice Valuelite we have on the lot!  Cheers! 

YOU HAVE GOT TO BE KIDDING! THIS IS A JOKE, RIGHT?

And that my friend would be the reason I don't own one. A dealership in Oklahoma is filled with a BUNCH of rude people but only AFTER you buy a trailer from them....

Hounddog

I don't want to start a jousting match, but what you're saying is absolutely false. Either you are blindly accepting the veracity of experts who obviously have never set foot in this area, or you have no context as to real world conditions.

First I'm told that all trucks and cars have under coating from the factory, mine don't, and now I'm told that the rust buckets that I've owned and the similar ones I pass daily, don't exist.

I won't get crude and tell you where you've been looking. I have lived in NY and PA all my life. I am particularly familiar with what I see on a daily basis. What you are describing is not true. A ten minute visit to my locality would prove how wrong you are.

You will have to find some other "experts" who have actually seen what they so poorly describe. The title of a book "Don't piss on my leg and tell me it's raining" is my most apropos answer to your statements.

Gard

Why does everyone have to "piss on someone's leg."  Let your yes be yes and your no be no.  If you don't agree with someone, challenge them for some sources, and smile.  You don't have to make comments about someone you don't agree with.  This is what scares people away . . . with valuable input.

Some call it bullying. 

And if you're challenged, smile for the opportunity to quote some sources.  If they still don't  believe you, move on.  You've done your job.  If you're using the board to "win" arguments and throw cute one-liners, you don't need to continue. 

Ex.) Most of us understand that great improvements have been made against rust.  (I've owned that Ford, over the wheel well rust bucket in the sixties, and now an eight year old modern version with NO spots above the wheel well, and I'm from Minnesota)  And most of us also know that rust is as sure as death and taxes.  So what! 

Something else I found interesting was that the same day I sent them the info I rec'd here and asked if it was true, I sent them a different question. They IMMEDIATELY answered the other question I had (a weight question about one of their trailers), but it took several days to get the response I posted above.

Bettylou

Send him/her a PM. You can tell if and when he/she received it, and you'll know if you're being ignored.

Gard

I have a 2000 Chevrolet K2500 that is showing rust thru in the floor of the cab at the door opening and no where else...

No, there could be hundreds/thousands of these out there.

I have used Dupli Color successfully for years, as well as several members of our club who I helped to install it. During the year, about once a month I hose out the floor without removing the mats. At the end of the season I pull the mats and pressure wash the whole floor, top and bottom. The material looks like new and has performed flawlessly.

Since you did not personally apply your surface, and I have successfully done several, I can only speculate that the instructions were not followed correctly. This may be the reason for your bitterness, when it apparently has had subsequent issues.

This product can be applied over an unprimed surface. I have done so and it works as advertised. I and several other people I know are very pleased. I can't say any more than that.

To lump all additive coatings into a do not use category, because of your issues, would cause a disservice to those who could benefit from them. I have no ties to this product, other than it provided the means to an outcome I desired.

Gard

It's been my experience that the only people that don't make mistakes are those who do nothing and who complain the most.

My life has been an accumulation of mistakes. I worked on commercial aircraft for 34 years and built boats for 19. I've never had the privilege of being a cowboy, I doubt that I'm man enough.

Just what mistake should I now be held responsible?

Gard

I thought anytime you tried to paint/apply a coating to aluminum you had to use the etching type primer. I seem to remember in the military they use it on planes(it's kind of an ugly greenish color), I know I have painted some aluminum in the past and had to use it then. It has some type of acid in it because they package it in glass.

If you use muriatic acid before applying any type of finish to aluminum, it will stop any oxidation, clean the aluminum and it will etch the metal. This ensures a good bond. It's this step, that most people who are complaining about an insufficient adhesion, have neglected to administer.

Aluminum, whether it is drawn, rolled, cast, forged or extruded is usually too smooth for the application of most common paint products to perform well. The correct steps have to be followed. Neglecting any of them will result in an insufficient adhesion.

The "green" stuff is called Finch primer. It is commonly used in the aircraft industry on surfaces that will be coated. It does not stop active oxidation and is only applied to new or refurbished surfaces.

Gard

Well Tx. ticked him off, then I tried to explain Tx.'s point, and ole Gard let me have it in a private message. I don't understand the whole ripping someone in a private message. I guess thats the difference in folks like him, and folks like me, If I got something to say to you, I'll say it in front of everyone.

I think we need to get back on track with this thread. I have an interest in hearing from Sundowner dealers ect as well. I owned an 01 3H slant Valuelite a few years ago. When a prospective buyer pointed out to me they didn't like the looks of the frame.. I said "huh"?? Upon crawling under the trailer and viewing the decaying "spray on coating" and subsequent rusty flaking of the actual steel frame I was a tad concerned. I had purchased this trailer used and had barely used it myself.  I chalked it up to a fluke with that particular trailer. Now.. I am tending to think otherwise. I would like to know from 3 Yr Hitch...     When an owner is in debt out the wahzoo on a Sundowner (most of us normal buyers are)...   what are they supposed to use for a means of hauling their horse if their pricey Sundowner is in the shop getting stripped and repaired? Of course they are still making a payment on the trailer during this time. Just curious how that works?

Edit for spelling

 Well said!