Been there, done that. Doing it again right now as well. We learned about DR after hitting a rough patch in 2001. We've lived comfortably since then, built an EF. But, we still have moments like we are right now.
Beginning in 2010, my income dropped by about 10%, then our car started to have problems (two years earlier than we had hoped) and we had to put some costly repairs in. We also had to replace our truck. We had 2/3 of cost to put down, but still had to take out a small loan for the remainder at 2.5% interest.
In the fall, our teen was diagnosed with a rare condition effecting her vision and had to have outpatient laser surgery to stop the progression of the disease twice. We got nailed with our medical deductible for both procedures (end of 2010/beginning of 2011) and our 30% of the balance. She also had to have some pricey cardiac testing done following her pre-surgery physical to eliminate concerns from her EKG. (The final diagnosis was that she had four "normal abnormalities."

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We are back to making payments on debt for the first time since 2002, granted most of it is 0% interest. We could use the EF, but it would hurt. And, it's possible she will continue to need more care, some of which are not covered by insurance. So, we opted to do the payment plan and hold onto our cushion in the bank, just in case.
It's frustrating to feel like you are back to a paycheck to paycheck lifestyle.