Aerolite travel trailers are a premium product of Dutchmen RV, and they are known for being lightweight, easy to tow, and comfortable. But just like any other top RV maker, there are some customer complaints. So, if you’re considering purchasing this RV brand, it’s important to educate yourself on the most common Aerolite travel trailer problems.
Overall, Aerolite RVs have an average of good quality. On RVInsider — the leading source of actual RV reviews by owners — Aerolite trailers have a score of 3.7 out of 5 stars from 18 reviews. This is a decent score since other Dutchmen brands average 3.4 stars from 412 reviews.
This post will highlight the major and minor Aerolite issues so you can make an informed choice when buying.
A Brief History of Dutchmen Aerolite
The Aerolite brand first hit the dealerships in 1996, making it one of the oldest continuous brands of Dutchmen. Over the years, Aerolite has produced a variety of travel trailers and fifth wheels ranging from 16 to 37 feet in length. From the onset, Dutchmen’s goal was to make the Aerolite as light as possible. In fact, they traveled to Europe to study its market since most people there don’t use powerful pickups and large SUVs to tow because they prefer lighter trailers.
After extensive studies, they decided to focus on the main qualities customers want in a small trailer: an enclosed bathroom, a full galley, and generous storage while still offering ample living room. The Aerolite brand has delivered on this promise with units that are super-easy to tow, outfitted with comfort amenities, and featuring slide-outs to expand the living space.
Side notes:
- Dutchmen quietly discontinued the Aerolite lineup in 2020. However, there are many dealerships across the country with new and used Aerolite trailers. Aerolite is a popular model, so don’t be surprised if it makes a comeback after a few years.
- Aerolite’s parent company, Dutchmen, was founded in 1988 and is a division of Keystone RV. It’s based in Goshen, Indiana. In 1991, Thor Industries acquired Dutchmen after 4 years of operation. However, Dutchmen still operates independently and continues to develop its own branded units.
Dutchmen Aerolite Floor Plans and Features
Aerolite has many unique campers, and their models and floor plans change almost every year. Generally, their trailers feature between one and three slide-outs, have 3,000 to 8,500 lbs of empty weight, and sleep between two and 10 people. Buyers have a wide range of layouts to choose from. You can opt for a floor plan with a bunk room, master suite with king/queen bed, front/rear bedroom, two entry doors, theatre seating, standing/u-dinette, a big outdoor kitchen, and/or a kitchen island.
Indeed, these trailers have nice standard features like powerful air conditioning, a tri-fold sofa, good quality furniture, huge stainless steel appliances, solid-surface countertops, LED HDTV, lots of large windows, a thermal package, a gel-coat finish, and decent interior height. Some models also come with an elegant fireplace, pass-through storage, a power awning, and a double door refrigerator. You’ll also have a control system that lets you monitor and operate various electrical functions throughout the camper from your smartphone.
Optional features include aluminum rims, frameless windows, bedroom AC, and a black tank flush. The MSRP of a new Aerolite ranges between $35,000 and $50,000 based on the model and features you pick.
Now, what are the issues associated with Aerolite trailers?
5 Common Dutchmen Aerolite Travel Trailer Problems
While Aerolite trailers excel in many departments, there is no perfect RV. So, expect some quality issues. The good news is that most of the concerns owners have are covered under the warranty. Here are some of the most common Dutchmen Aerolite travel trailer problems:
Soft Floor
One of the main Dutchmen Aerolite complaints is about soft floors. Many owners say that some sections of their floors feel like they are sinking. While this mainly occurs on the bathroom floor or the area around it, some people report that the entire floor is soft.
Cause: The soft spots on the Aerolite travel trailer floors are mainly caused by three issue — water damage from hidden leaks, structural flaws, or pre-mature breakdown of the foam core layers sandwiched between two plywood sheets.
Solution: The best solution is to cut out the damaged sections of the floor, measure the area, and replace it with brand-new wood of the same thickness. Make sure you secure the new section to the beams or joists using decking screws. In some cases, the manufacturer may not have added enough cross beams or joists to support the floor. If this is the case, you’ll need to add support cleats before installing a fresh floor.
Water Leaks
Another one of the Dutchmen Aerolite travel trailer problems is water leaks. These leaks don’t just originate from the roof. Owners report water seeping in through windows, doors, hatches, skylights, slide-outs, and even through the refrigerator vent. Some leaks occur internally through the plumbing system, such as around the sinks, water heater, and pipe joints. If not detected early, water intrusion can cause a string of other severe issues like rotting walls and floors, mold, and rust.
Cause: The main reason behind the external leaks is poor sealing. The manufacturer either installed the sealant improperly, used a poor-quality product, or skipped some sections entirely. Sometimes, it’s the owner’s fault when they forget to maintain the seal. Internal plumbing leaks mostly appear around connections. They can be tough to pinpoint due to the complex maze of pipes that are out of sight.
Solution: The best way to solve leaks is to inspect all seams and caulk in detail, find the source of the water intrusion, and then seal the holes with a generous portion of silicon sealant or caulking. For plumbing line leaks, shut off the water to your RV, drain the water in the lines, cut and remove the affected part, and replace it with a new pipe.
Delamination
One more Aerolite RV owner’s nightmare is delamination of the side wall, front cap, or roof. Put simply, delamination is when the material you see on the exterior of your RV begins to bubble or separate from the material it’s attached to, most often plywood. This is common with RVs that have fiberglass skin. The area can look like it’s bowed out, bubbling, or tearing apart.
Causes: Water is the leading cause of delamination in all RVs, including Aerolite travel trailer brands. The problem is usually more serious than just the area that is visible. Before bubbles appear, the water may have already caused bigger structural problems, like a rotting floor, a damaged frame, or mold. Sometimes, the issue can be cosmetic—just a simple adhesive failure between the outer layer and the backing material.
Solution: Delamination requires an in-depth inspection by a professional. That’s because it’s tough to tell the extent of the problem because it’s hidden behind the walls. Once the expert identifies the level of damage, they can suggest a fix. For serious damage, you’ll have to strip and replace the entire exterior panels. And that’s expensive and time-consuming. For cosmetic issues, use a delamination repair kit to glue together the separated layers.
Slide-out Issues
Owners of Aerolite Dutchmen campers also complain that the slide-outs won’t open or close. One owner of an Aerolite Cub didn’t have a manual, so they were unable to diagnose the slide issue.
Cause: Most times, the slides fail to operate correctly due to motor failure, power issues, switch problems, or jamming due to lack of lubrication or debris. In some campers, the issues are more serious. In another Aerolite Dutchmen RV review on RVInsider, an owner claims that the dealer told them the manufacturer wired the slide-out cables incorrectly.
Solution: Fixes range from lubricating the slide out, checking your battery’s state of charge, testing the switch, and checking your power center fuses and breakers. If you aren’t comfortable troubleshooting the slide, get professional help.
Bent Frame
A bending frame was another serious issue that appeared in older models of Aerolite RVs. While it’s common for frames to flex a little, bending or twisting is a disaster. For some owners, they only discovered the problem after taking the RV to the shop to fix unrelated issues. For others, the frame suddenly bent and damaged the floor. Most of the people who have experienced this headache say they never hit anything, ran over anything, jacked the frame up, or abused the trailer in any way.
Cause: Dutchmen’s attempt to build a trailer that is as light weight as possible led it to inadvertently use some frames that had insufficient thickness. As you rack up miles, the frame may start to bow. One owner reported that the frame bent because of loose bolts on the axle.
Solution: If you’re suspecting a bent frame, contact a well-reputed frame repair shop that deals with heavy-duty trailers. They will open the undercarriage, inspect it closely, and then straighten and reinforce it if the problem isn’t severe. For more serious damage, like complete breaking, a frame specialist can cut out the bad part and weld in a replacement plus support. This is a manufacturing defect that should be covered by the warranty.
Other Minor or Cosmetic Issues of Aerolite Travel Trailers
Here are other smaller issues that plague Aerolite RVs:
- Fridge not cooling
- Awning not properly secured
- Auto-leveling system doesn’t work
- Water heater leaks
- Skin oxidation — more of a cosmetic issue
Unfortunately, Dutchmen has been reported to deny claims even when the issue is covered by warranty. Aerolite owners have rated the reliability of its factory warranty 2.7 out of 5 stars, which is something to keep in mind.
Aerolite Travel Trailer FAQs
Here are some frequently asked questions regarding Aerolite Travel Trailers.
Do They Still Make Aerolite Travel Trailers?
Dutchmen stopped making Aerolite campers in 2020. They didn’t state why, but it was a pretty popular model. But some dealerships still have new Aerolite RVs from previous years. You can also buy used ones from private owners or dealerships.
Are Aerolite RVs a Good Brand?
A Dutchmen Aerolite RV is a fairly good brand if you’re looking for an entry-level trailer. However, some of their models fall short on quality workmanship. So, you’ll need to research which model year has fewer issues before buying.
Many Aerolite Travel Trailer Problems are Fixable
Just like any other recreational vehicle brand, Aerolite trailers have room for improvement. Many of their issues stem from poor workmanship during the construction process. Dutchmen can fix the problems by improving their quality control inspection procedures. This will help them catch any defects being produced before the RV is shipped.
To avoid buyer’s remorse, buy new so that the RV warranty covers any components that fail within the first 3 years. You may also want to buy an extended warranty to prolong the manufacturer’s coverage. If you want to buy used, pay for a professional RV inspection, and you’ll avoid inheriting another person’s problems. Of course, some Aerolite models have more problems than others, so you’ll need to do extensive research.
More from RV Top Tips:
Cynthia Measom is the founder and main content creator of RV Top Tips. Not just a writer, she’s a dedicated RV owner and enthusiast, alongside her husband, Joe, who is an experienced RV tech. With their joint knowledge, the two are up on the latest trends and technologies in the RV industry, as well as practical camping and lifestyle tips.
The couple own a 2020 Coachmen Chaparral fifth-wheel that they absolutely love. Their secret to being so satisfied? They purchased the model after a solid year of researching different fifth-wheel campers in person and online to find the perfect fit for their family of three.
- Cynthia Measomhttps://rvtoptips.com/author/admin_rvtoptips/
- Cynthia Measomhttps://rvtoptips.com/author/admin_rvtoptips/
- Cynthia Measomhttps://rvtoptips.com/author/admin_rvtoptips/
- Cynthia Measomhttps://rvtoptips.com/author/admin_rvtoptips/
