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?