This sounds like stress cracks caused by flexing of the front cap around the hard points of the trailer's house walls. This could be a design problem (insufficient structural integrity of the coach), or a build problem (improper mix of fiber and resin or inadequate thickness of the cap layup), or an assembly problem (cap not properly mounted to the house).
There are two types of stress cracks; superficial cracks in the gelcoat & cracks in the fiberglass structure. Minor cracks in the gelcoat can often, but not always be ignored as they are often cosmetic only. Cracks in the structure of the cap are obviously more serious.
First, I'd contact the manufacturer and see if they will offer any relief.
Second, I'd take it to an RV repair facility experienced in RV body/crash damage repair. A marine facility may be better at the GRP repairs, but they won't have the experience in how the RV is built.
Steve & C. J.
"Gracie" the Rough Collie & "Bo'sun" the Bichon Frise
I've read some pretty promising threads on the Goin' KZ forum about KZ stepping up to the plate even after the warranty has expired. It may be the best place to start anyway. My '02 KZ 2505 developed it's first crack on the front nose cone this year. I applied a bead of caulk to seal out the water for now. I'm sure they will not work with me on mine...bummer!
Mark & Kim
Kaylee, Jake & Justin - da squids
2000 Jayco Eagle 325 BHS
'05 Chevy 2500HD Crew Cab 4x4 Duramax
New pic coming soon!!!
Any marine supply store should carry a gel cote repair kit. Just remove the loose material and smooth in the gel coat (it's a two part mix). Cover with some plastic and let dry. Finish with some wet sanding and polish.
Had a similar problem with my '06 KZ Frontier, took it to the dealer, they contacted KZ, and now I have a new re-enforced nose cap. Course it was still under warranty at the time. KZ is aware of the pre-'07 nose cap problem and to my knowledge has made good on all complaints.
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