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Author Topic: 1991 Jayco roof sideboard replacement  (Read 5042 times)

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Offline SCBrian

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1991 Jayco roof sideboard replacement
« on: April 23, 2009, 09:47:48 AM »
Over the course of the next few weekends I'm going to start replacing 2 dry rotted 'sideboards' on the roof. I've looked around on the site and have a general idea of what is involved, but I'd love to ask a quick question to someone who has handled one similar.
#1 Is the roof all one piece? I.e. Does the aluminum on the 'roof' continue down onto the 'sideboards' or is each piece separate? I'd love to know this prior to tearing into it.

My initial plan (If the pieces are separate) is to remove the front and side 'sideboard', and replace with 3/4" ply that has been sealed with Thompsons. The front board should be quick and easy. The 'side' one should be a little more fun. I'll need to take 2 pieces of plywood (Due to length) and attach the butt ends together to make the total length. What is the best method of attaching these together? Everything will be reattached and clamped back down. New weather stripping added, and the roof re-caulked / sealed. Is there anything else I should know up front or anything I'm missing? Any comments or advice?
 
Thanks!


Offline jallen37

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1991 Jayco roof sideboard replacement
« Reply #1 on: April 23, 2009, 11:41:57 AM »
SC, we just recently replaced both side boards and the rear board on the roof of our 1991 Jayco. Unfortunately, me being a girl, I was only in charge of purchasing the supplies from the list DH and his brother gave me. They did all of the labor so I don't have a lot of info to give. I will check w/DH and let you know what steps they did and how they did it.

Jerri and Matt
Tobey the dog
91 Jayco PUP/95 Ford F-150

Offline RFryer

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1991 Jayco roof sideboard replacement
« Reply #2 on: April 23, 2009, 12:26:43 PM »
I'm sure your roof is like my Rockwood, which I am currently rebuilding the sides on, and is in multiple pieces. The sides and front boards are separate and screwed/nailed to the top and covered by the trim and caulk and butyl tape. Fun stuff to remove! I'm doing what others have done and using a lap joint (about 8" overlap) to join 2 pieces of 15/32 plywood and reinforcing it with dowls (as far as I've gotten so far. I'll then seal and prime it and cover the outside with vinyl flashing. I have a few pics under my camera icon but need to get some more up this weekend.

Ray

PopUp 96 Rockwood 1908
Tow Vehicle 2005 Honda Odyssey
Ray '75, Julie '74, Connor '07, Haley '10 [TV] 2009 Honda Pilot [PU] 2007 Utah
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Offline RFryer

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1991 Jayco roof sideboard replacement
« Reply #3 on: April 23, 2009, 12:28:54 PM »
Search for the thread "starting roof repair today". It's a good one that I've been using.

PopUp 96 Rockwood 1908
Tow Vehicle 2005 Honda Odyssey
Ray '75, Julie '74, Connor '07, Haley '10 [TV] 2009 Honda Pilot [PU] 2007 Utah
The toys go where we go

Offline SCBrian

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1991 Jayco roof sideboard replacement
« Reply #4 on: April 23, 2009, 01:53:58 PM »
Thanks for the responses, and the thread. I'm not sure how I missed that one. I just hate hopping into a project with out knowing what will need to be done. Is trying to save the aluminum or vinyl a lost cause or did you just have to replace it in yours?


Offline RFryer

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1991 Jayco roof sideboard replacement
« Reply #5 on: April 23, 2009, 03:05:26 PM »
I was hoping so save mine, but between it had a few small tears in it where the supports mounted and it also would have been very time consuming removing the solid wood (about 50% of the side) from the fiberglass. The rotted part peels off easily. The inside panels are ripped and trashed, as most do I'm not putting anythig on the inside since you can' t see it anyways. My wood was so rotted I had several worm larvae in there.

Ray

PopUp 96 Rockwood 1908
Tow Vehicle 2005 Honda Odyssey
Ray '75, Julie '74, Connor '07, Haley '10 [TV] 2009 Honda Pilot [PU] 2007 Utah
The toys go where we go

Offline SCBrian

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1991 Jayco roof sideboard replacement
« Reply #6 on: April 23, 2009, 03:40:04 PM »
Ack. I'll have to take pictures of the progress. Hopefully nothing as bad as yours but I know both panels need to be pulled. In the side one the dryrot covers ~50% and in the front one it's conviently in the locations the bunk canvas supports go... I figure I can replace the whole thing as easy as trying to replace just some of it...