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Author Topic: Whole roof replacement, Completed 6/12/07  (Read 4860 times)

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Offline shocker

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Whole roof replacement, Completed 6/12/07
« on: May 08, 2007, 04:07:34 PM »
HI all
I'm new to the camper field but not the fixing field. We bought a 1978 Jayco King about 2 weeks ago. I knew the rear and right side panels on the roof would need some attention, but man I did not realize just how bad the whole roof was.

All the foam between the ceiling and the outer metal is soaked and rotten. The frame rail that everything attaches to is also rotten and fallen apart. So I am going to build a new and improved roof.

I have measured and remasured all the dimisions. So here is my ideal. Tell me what you think.

For the frame I will use 1x2 just like it has. It will set 1/2" below the top of the side panels.

The new side panels will be made out of 1x8 planed down to a 1/2". I am doing this insdeat of plywood so I can have one solid peice on the sides.

For the roof I am going to place 1/2 plywood across it. gluing and sealing all seems. This will set flush with the top of the side panels.

I will use the orginal outer roof metal. It is in good shape still, just need to get all the old foam and sealer off it.

For the ceiling I will use sheets of aluminum. With faom between the plywood and the ceiling.

After I get the ceiling rebuilt and working I will attach the canvas back to it using industrial velcro. (the plastic that the canvas attached was destroyed when I was removing it.)

Will this work? Will it be to heavy? I wieghted a 4" x 8" peice of foam that fell out of the ceiling and it wieghts 2 1/4 lbs wet. and the whole ceiling is that wet. I think it will be ok.

Seems like a lot of work but I am up for it and will take pride knowning I did it.

Updated the web page Roof Repair


Edited by - shocker on May 08 2007  16:08:35

Edited by - shocker on May 14 2007  00:02:06

Edited by - shocker on May 27 2007  01:00:41

Edited by - shocker on June 02 2007  11:14:40

Edited by - shocker on June 12 2007  09:39:59

Offline Fairview 2001

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Whole roof replacement, Completed 6/12/07
« Reply #1 on: May 08, 2007, 04:22:10 PM »
I rebuilt a roof myself for a Starcraft. You may still be able to buy the plastic needed for attaching the tenting. Check online and I am sure you will find it. For the roof I would use marine grade PT plywood.

Ron & Barbara
'01 Coleman Fairview W/GlideOut
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Edited by - Fairview 2001 on May 08 2007  16:22:44

Offline jhower

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Whole roof replacement, Completed 6/12/07
« Reply #2 on: May 08, 2007, 04:39:25 PM »
It certainly sounds as if you know what you're doing and know what you're in for, so you're way ahead of the game, shocker.

It should be OK as far as weight goes. While you're rebuilding the roof, take a look at the cables to be sure they're in good shape. And, of course, lube the whole lift system so it's not straining against itself to lift the roof.


John & Cindy in Pennsylvania
-For Sale-'89 Coleman Sun Valley
2007 Flagstaff 620ST
'95 Dodge Dakota 4x2 3.9L
His & Hers Pelican kayaks
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John & Cindy
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Offline shocker

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Whole roof replacement, Completed 6/12/07
« Reply #3 on: May 08, 2007, 09:13:06 PM »
I checked all the cables before I bought it. The only one that needs replaced is the main cable and I have the repalacement just need to get it on.

Was thinking about 1/4" plywood instead of the 1/2" across the roof. Not sure which I will get yet.

 

Offline jhower

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« Reply #4 on: May 09, 2007, 06:04:28 AM »
Using 1/4 inch would keep you closer to the original weight. If you use 1/2 inch and add some cross braces you'd never have to worry about the weight of an A/C unit, if you want to go that route.


John & Cindy in Pennsylvania
-For Sale-'89 Coleman Sun Valley
2007 Flagstaff 620ST
'95 Dodge Dakota 4x2 3.9L
His & Hers Pelican kayaks
http://community.webshots.com/user/jhower55
John & Cindy
'04 F150 Lariat, '08 Fleetwood Niagara

Offline shocker

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Whole roof replacement, Completed 6/12/07
« Reply #5 on: May 10, 2007, 05:45:12 PM »
I am not sure if my metal will be worth safing after I get it all off. I was wondering if the EPDM Rubber Roofing system would work? http://www.go-rv.com/coast/do/catalog/page?dealerId=66&pageNum=134
I will have all new wood under it and it seems like it would be the best investment since I am rebuilding the whole thing.

 

Offline shocker

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Whole roof replacement, Completed 6/12/07
« Reply #6 on: May 14, 2007, 12:10:39 AM »
Here is a link to my roof rebuild. I am tring to document everything and take pictures as i go.

http://www.shockersgarage.com/roofrepair.html

 

Offline jhower

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Whole roof replacement, Completed 6/12/07
« Reply #7 on: May 14, 2007, 08:29:03 AM »
Your documentation, I'm sure, will be appreciated by others facing a roof rebuild.

It's looking good so far!


John & Cindy in Pennsylvania
2007 Flagstaff 620ST
-SOLD-'89 Coleman Sun Valley
'95 Dodge Dakota 4x2 3.9L
His & Hers Pelican kayaks
http://community.webshots.com/user/jhower55
John & Cindy
'04 F150 Lariat, '08 Fleetwood Niagara

Offline shocker

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Whole roof replacement, Completed 6/12/07
« Reply #8 on: May 15, 2007, 04:40:41 PM »
Just a update, I have been looking for new aluminum to replace the old top and the sides with no luck. Today I thought,self call the metal place you got the metal from for the barn. Well sure enough they sell it. They said that they get hugh rolls of flat metal that forum their siding from. Its 29 gauage tin but it will work and it is not going to cost that much. They will cut in one big roll for me or to the sizes I need, but it will take about a week to get.

 

Offline shocker

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Whole roof replacement, Completed 6/12/07
« Reply #9 on: May 27, 2007, 01:05:55 AM »
Just thought I would give a update. I have the metal and it is cut and molded to form now. Waiting on some help to get it glued down. I am also working on the inside. check out my web page for all the details.

roof repair page

Edited by - shocker on May 27 2007  01:27:09

Offline jhower

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Whole roof replacement, Completed 6/12/07
« Reply #10 on: May 27, 2007, 07:24:48 AM »
Looks like it's coming along pretty well.


John & Cindy in Pennsylvania
2007 Flagstaff 620ST purchased 05/07
--------------------
'89 Coleman Sun Valley, sold 05/07 and headed for Louisiana
--------------------
'95 Dodge Dakota 4x2 3.9L
His & Hers Pelican kayaks
http://community.webshots.com/user/jhower55
John & Cindy
'04 F150 Lariat, '08 Fleetwood Niagara

Offline rmassing

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Whole roof replacement, Completed 6/12/07
« Reply #11 on: May 27, 2007, 10:11:52 AM »
Nice Pic site.  Enjoyed looking at your rebuild. Let me know if all that plywood adds a lot of weight to the camper.  I might try to build mine in the same way.

Robert
Sherry
Jessica 11
Samantha 8
William 5
1995 Merc Villager
1992 Palomino Filly
Robert, Sherry, Jessica(DD), Samantha(DD), William(DS)
2002 Ford Expedition[TV], 1992 Palomino Filly[PU]

Offline LauraD73

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Whole roof replacement, Completed 6/12/07
« Reply #12 on: May 29, 2007, 01:39:13 PM »
I really enjoyed the pictures of your roof replacement! I just got a 1977 Starcraft from my aunt, and knew it had roof issues. The rail holding the canvas up on the roof was falling off in places, because the wood inside wasn't solid. When we got it home and set it up, wind caught the canvas, and ripped 80% of it off. We did a temporary fix by putting wood scraps around the outside to screw the rails into. I don't know how long it will last, but I hope to get it through this year, then re-build the roof this winter.

 

Offline shocker

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Whole roof replacement, Completed 6/12/07
« Reply #13 on: May 29, 2007, 07:00:02 PM »
thanks for the comments.

I am not sure how much wieght it will add. I can still pick it up by hand just like the old one. But the old one was very water logged and is still wet after a couple weeks being off.

I have about 25-30 hours into. working when I can.

 

Offline shocker

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Whole roof replacement, Completed 6/12/07
« Reply #14 on: June 02, 2007, 11:16:46 AM »
Well we have one side complete. I updated all the pictures on my web page. Hopefully we will have the other side done to night. Then just have to get the marina goop and seal everthing good. http://www.shockersgarage.com/roofrepair.html

 

 


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