Split Loading Ramp Door

This seems to be a common problem in the online Keystone forum. It only seems to affect the smaller doors. I don't know how the door is manufactured but from the outside it looks like two sheets of material are butt joined in the center of the door but the edges are not connected in any way. As loads are applied to the door the two sheets of material move independently. This stretches the non skid rubber coating and eventually forms a raised seam directly over the joint.

I don't understand why a loading ramp would be made of two pieces of material butt joined in the middle of the ramp.

Keystone replaced the ramp once under warranty. I have never overloaded the door. I have a 2006 Gold Wing motorcycle and the total weight with me on it is probably around 1,150 pounds. The door is rated for a total of 1,600 lbs with a maximum of 1,000 lbs per wheel contact.

The replacement door started showing the same problem after only 2-3 uses. I called Lippert this time because I was past the 1 year warranty. After viewing the photos they agreed to replace it again and they will cover the cost. No one could explain to me why the doors were defective. They also would not guarantee the new door is good. They had a "wait and see" approach.

So for now I am happy with Lippert as they are addressing the problem. I just don't want to have to replace it again. I had applied a neat decal on the door that I will now have to replace.

There are two sets of photos below. The original door showing the defect and the replacement door showing the same problem.

Original Door

Replacement Door With the Same Problem