# Case Studies > Representative jobs and what they took. Source: https://ocrv.info/resources/case-studies ## Curbside impact on a 38 foot gas Class A Vehicle: 38 foot gas Class A motorhome. Damage: Driver side contact with a concrete pillar at low speed, crushing the entry step area, tearing the sidewall laminate across two bays and pushing the compartment door frames out of square.. Turnaround: Five weeks. - Teardown of the affected sidewall to expose cage framing and wiring - Two cracked aluminum uprights sectioned and welded at load appropriate points - Laminate rebuilt with a stepped scarf and biaxial reinforcement, core boundary cut back to dry material - Both compartment door frames rebuilt square and rehung - Sectional refinish with a planned blend across the adjacent panel Teardown found the impact had traveled about eighteen inches past the visible tear, which the first estimate did not include. A documented supplement with photographs of the cracked uprights was approved without a reinspection delay. The rebuilt section measured within a sixteenth of the opposite side across the bay openings, and the blend reads clean in raking light. The owner traveled from Eastvale for drop off and picked up on the scheduled date. ## Front cap delamination on a triple axle fifth wheel Vehicle: 40 foot triple axle fifth wheel. Damage: A wave visible in the reflection across the upper front cap, hollow on the tap test over roughly nine square feet, traced to a failed seam at the cap to sidewall transition.. Turnaround: Six weeks. - Moisture mapped on a grid and recorded before any material was removed - Delaminated area bounded by tap test and confirmed with a pinless meter - Wet lauan removed, framing dried and inspected, replacement substrate bonded in - Laminate reconstructed and vacuum clamped through cure - Cap seam reworked with correct sealant chemistry and the front graphic panel reproduced The failure had been progressing for at least two seasons, and the substrate behind the bubble was soft well past the area that sounded hollow. Cutting to sound material added square footage but removed the reason it would have returned. The finished cap holds a straight reflection along its full width and passed a sustained water test with the interior ceiling panel open. Deck and framing readings came back dry at reassembly. ## Membrane replacement with partial deck on a travel trailer Vehicle: 31 foot travel trailer. Damage: Chalked and cracked EPDM with lifting seams at four penetrations, a stained ceiling panel above the rear bunk and a soft area at the rear roof corner.. Turnaround: Three weeks. - Old membrane and all roof mounted hardware removed - Deck probed across the full length, with roughly twenty square feet replaced at the rear corner - New membrane installed with correct adhesive and open time for shop temperature - Every penetration reset on fresh butyl and topped with self leveling lap sealant - Edge trim replaced and the interior ceiling panel section renewed The owner had been resealing the same corner annually, which is a common pattern once decking is wet. Pulling the membrane showed the rot extended under the rear cap seam where no amount of surface sealant would have reached. Replacing the deck section was the difference between a repair and another year of the same problem. A sustained spray test with the ceiling open showed no ingress anywhere along the roof. ## Schwintek slide that would not retract square Vehicle: 34 foot Class C motorhome. Damage: Bedroom slide binding on retraction, one column ratcheting audibly, worn gear teeth on the leading edge and a wiper seal torn through at the top corner.. Turnaround: Eight days. - Systems diagnostic at the posted diagnostic rate, credited against the authorized repair - Both drive columns inspected, one motor and gear rack replaced - Room shimmed and re-timed, then cycled repeatedly under observation - Wiper and bulb seals replaced on all four sides - Slide topper fabric inspected and its mounting hardware resealed The binding was mechanical rather than electronic, which the controller fault code did not make obvious on its own. Worn teeth on one column let the room walk out of synchronization, and each cycle made the next one worse. After re-timing, the room seats evenly on all four edges and the seals compress uniformly, which is the actual point. The owner was shown the worn rack alongside the replacement at delivery. ## Rear quarter damage on an upfitted Sprinter van Vehicle: 170 inch wheelbase Sprinter camper van. Damage: Backing contact against a loading dock corner, creasing the rear quarter panel, distorting the door aperture and disturbing the interior cabinetry and wiring behind the affected wall.. Turnaround: Four weeks. - Interior cabinetry and wall panel removed and catalogued for reinstallation - Unibody measured, aperture pulled back to reference on a rack - Rear quarter section repaired and the door adjusted to consistent gaps - Disturbed twelve volt circuits and the rear camera lead tested energized - Refinish with blend into the sliding door and roof edge Upfitted vans complicate collision work because the build hides the structure. Removing the interior added labor but was the only way to measure the aperture honestly and to confirm no wiring was pinched during the pull. Door gaps came back within a millimeter side to side, the rear doors latch without lifting, and the reinstalled cabinetry sits on its original mounts. The camera and lighting circuits were verified under power before panels closed. ## Water intrusion rebuild in a toy hauler garage wall Vehicle: 36 foot toy hauler. Damage: Soft flooring at the base of the garage side wall, staining behind the ramp door hinge line and a musty odor traced to saturated substrate running about eleven feet.. Turnaround: Five weeks. - Flooring and lower wall panels removed to expose framing and subfloor - Subfloor sections replaced where probing found no remaining structural value - Ramp door hinge line rebedded and its fastener pattern corrected - Wall cavity dried and verified with meter readings before closing - Interior panels, trim and flooring reinstalled and the area repainted The leak entered at the ramp door hinge fasteners, which had been sealed over rather than pulled and rebedded during an earlier repair. Water tracked along the subfloor and surfaced eight feet away, which is why the owner had been chasing the wrong wall. Removing the flooring made the actual path obvious in ten minutes. Meter readings were documented at teardown, mid dry and at close so the file shows the progression. ## Corner post and liftgate damage on a delivery box truck Vehicle: 26 foot box truck with a rail liftgate. Damage: Rear driver side corner post folded inward after a dock strike, the roll up door track distorted, the reefer liner torn along the seam and the liftgate platform bent at the hinge line.. Turnaround: Nine days. - Corner post cut out and a new post fabricated and welded to the original section - Roll up door track straightened and the door retensioned to run without binding - Liner panel section replaced and the seam resealed - Liftgate platform straightened, hinge pins replaced and cylinder function verified under load - Conspicuity tape and rear lighting restored to their original layout Fleet downtime was the governing constraint, so the post fabrication started the same day the unit arrived rather than waiting for a parts quote that would have taken a week. The rebuilt corner measures square to the opposite side and the roll up door runs its full travel without a catch. The liftgate cycles to level and holds position under a loaded pallet. The unit went back into route service the following Monday. ## Hail damage across the roof and upper panels of a diesel pusher Vehicle: 43 foot diesel pusher motorhome. Damage: Dense hail dimpling across the fiberglass roof and both upper sidewalls, cracked roof air shrouds, a fractured skylight dome and gelcoat crazing over a wide area.. Turnaround: Seven weeks. - Full photographic damage map with a scale reference for the carrier file - Roof surface repaired and refinished after crazing depth was assessed by section - Two air conditioner shrouds and one skylight dome replaced - Upper sidewall panels refinished with blends carried into the body break line - Sealant renewed at every penetration disturbed during the work Hail files live or die on documentation because the damage is diffuse rather than concentrated. Mapping every dimple field with a scale reference let the adjuster approve the full roof and both upper panels in one pass instead of approving a section and returning. The refinished surfaces hold an even gloss across the length, and the reset penetrations passed a sustained water test before the unit left the delivery lane. ## House power rebuild on an owner built camper van Vehicle: 144 inch wheelbase camper van. Damage: Undersized cabling and missing overcurrent protection on an owner installed system, nuisance inverter shutdowns under load and a battery bank that never reached full charge.. Turnaround: Two weeks. - Load audit performed and an amp hour budget built from measured draw - Main positive path refused with a class T fuse and cable sized to correct the voltage drop - LiFePO4 bank installed with a DC to DC charger on the alternator path - Solar array rewired in series to an MPPT controller - Transfer switch and shore inlet corrected, then the whole system commissioned under load The original problem was described as a bad inverter. Measurement showed the inverter was fine and the cable between the bank and the inverter was dropping enough voltage to trigger a low input shutdown whenever the induction cooktop started. Correcting the conductor size and the fusing solved the shutdowns outright. Charge acceptance improved sharply once the alternator path went through a proper DC to DC charger instead of a relay. ## Interior rebuild in a truck camper after a leak Vehicle: 11 foot hard side truck camper. Damage: Swollen cabinet bases, a delaminated dinette seat platform and a wall panel that had separated from its framing after a long running leak at the roof vent flange.. Turnaround: Three weeks. - Roof vent removed, flange rebedded and the surrounding deck verified dry - Cabinet bases and face frames rebuilt in matching material - Dinette platform reconstructed and reupholstered in a matched fabric - Wall panel replaced and refinished to the adjacent surfaces - Twelve volt lighting circuits in the affected wall tested and reterminated Small units concentrate damage. Eleven feet of camper does not give water anywhere to disperse, so a slow vent leak reached three separate assemblies. Rebuilding the cabinet bases in matching material rather than patching them kept the interior looking original rather than repaired. The vent flange was rebedded on fresh butyl and the deck around it read dry across the full grid before anything was closed up. --- OCRV Center. 23281 La Palma Ave, Yorba Linda, CA 92887. (949) 799-3387. info@ocrvcenter.com. Serving Eastvale, California in Riverside County, about 20 miles from the shop. All work is performed in shop at the Yorba Linda facility. No mobile, roadside or on-site service is offered. Scope is body, paint, structural, fiberglass, interior and vehicle systems work. Engine rebuilds, transmission rebuilds, drivetrain work, DOT inspections and emission testing are not performed.