purchased a 2007 Sunline T2499 January 15, 2007. The trailer was manufactured May 4, 2006. I have towed the trailer about 10,000 miles and have found the same problem with the front cross-member. Both corners of the cross-menber appear to be sagging and the center section between the tongue rails is bowed backward and the welds have cracked. The battery "support" angle iron bowed upward. It appears to me that the weight on the corners of the cross-member caused the tongue frame to twist inward mostly at the bottom thus causing the center cross-member to flex backward. This then caused the battery "support" to bow upward. I think that the cross-member is not heavy enough c-channel and the battery "support" is way to light weight to effectively support the battery, and prevent the flexing of the tongue.
Could you email me or post to the forum a description of how the frame shop rectified the problem. Thanks in advance.
My thoughts were to strengthen the front cross-member by welding new c-channel over the existing one, but face it forward and use a heavier guage steel. Replace the battery supports with 2" angle iron with a 1/4" diamond plate floor on which to set the batteries.
I love the layout of this trailer, but what happened to the quaility of the build escapes me. But I guess this problem must be caused by insufficient engineering.
I don't have anything in writing to back this up, but the correct "factory" way to fix the undersized header on the Sunline 2499 is to have a 1" x 2" x 52" box channel welded to the bottom of the header connecting the right and left sides of the "A" frame. The frame shop repair didn't fix the problem by just straightening and rewelding the header but adding the additional box channel support appears to have fixed it. I've had no problem with the unit in 600 miles of travel since adding the box channel.
Since the repair, I also no longer have a large difference in the amount of weight on the spring bars between the street and sidewalk sides of the unit.
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