I figured I'd post this as maybe it will save someone else some potential grief. We have a 2011 Aerolite 185E purchased late Sept 2010. I have been very diligent with roof cleaning, checking caulking etc, I constantly check for potential leaks. Over the weekend I was getting ready to clean some small mildew spots on the side windows of the tent ends. I put down both ends. When I climbed onto the front door / platform without the mattress the pressure of my knee made a noise that will make you cringe. If you have ever heard plywood in a camper crack from water damage you know the sound. At the center, close to the hinge, the inside of the door is soft. I have never had noticed any water on the inside of the door either open or closed, and never even had a damp mattress or anything. Aerolite has a piece off rubber which covers the hinge / gap between body and door at the inside across the bottom. It is attached with aluminum trim strips. The soft spot was under this trim strip. So I stared removing the screws that secure this trim. While doing this I am thinking to myself "how the heck did this get wet". The only thing I could think was the top seal is leaking when the door is closed, water is running down the inside surface from the top, hitting this trim and getting behind it. But at the same time I have never seen water evidence, and I have looked at those seals during rain, after pulling in the rain etc. Well once I had the trim removed and was able to pull the rubber piece back I noticed that the screws that hold the door assembly together were rusty, below where the screw heads went into the door assembly also had some evidence. So out of curiosity I closed the door back up and at the bottom on the outside I noticed some slight buckling in the same area on the fiberglass at the outside, right where the fiberglass panel slides into the perimeter frame of the door. That is when I found it. The perimeter aluminum channel of the door is designed like an H, with one of the legs missing to make the flange that seals against the door seal. The caulking from the channel to the fiberglass had pulled away from the aluminum and had done so in a way that you could not notice it visibly. Until you took a screwdriver and played with it you could not tell it was separating. I came to feel this was where the water was coming in. With the front sloped like it is and the amount of water that comes down it, I could see water getting in to the break in the caulking. Once in there it would be inside the U which faced up of the perimeter door channel and able to wick up into the interior and exterior panels from the bottom. It then would drain out of the screws holding the door together. Once it drains out it can run to the sides of the channel that caps off the camper door opening bottom and out to the exterior. It looks like they have this piece designed so if water does happen to get in anywhere around the door it will not get into the body of the camper. I could not find any other evidence of water in the camper itself below the door. I would never have seen this visually unless I had removed the bottom rubber transition piece and really have never had reason to do that. Thankfully as long as I have stopped the leak I wouldn't consider the damage major, if the interior panel is weakend to the point it gets worse I can reinforce it. I intend to talk to my dealer and have sent an email to Dutchmen although it being out of warranty for a year I doubt they will do anything but you never know. It would be easy to change the entire door. The lesson I learned is to be way more thorough checking the caulking. Take a screwdriver or putty knife and play with it a bit. Once you go over it, go over it again. Another thing I noticed, I had always assumed the bunk doors were a piece of 3/4" plywood but now I believe they are an interior and exterior panel somehow applied to an aluminum frame? Anyone know for sure?