Whole roof replacement, Completed 6/12/07

Discussion in 'Roof/Floor Repair & Maintenance' started by shocker, May 8, 2007.

  1. shocker

    shocker New Member

    52
    0
    May 7, 2007
    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
     
  2. Fairview 2001

    Fairview 2001 New Member

    321
    0
    Dec 27, 2002
    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.

    <font color=red><center><img src=../Images/icons/icon_smile_ranger.gif border=0 align=middle> Ron & Barbara <img src=../Images/icons/icon_smile_bike.gif border=0 align=middle>
    '01 Coleman Fairview W/GlideOut <img src=../Images/icons/icon_smile_pu.gif border=0 align=middle>
    2004 GMC Sierra 1500 W/Sway Control
    3 Fantastic Boys</font id=red> <img src=../Images/icons/icon_smile_camping.gif border=0 align=middle><img src=../Images/icons/icon_smile_kayak.gif border=0 align=middle>
    Our General Store

    <font size=4>Click Here To See Our Photo Site</font id=size4></center>


    Edited by - Fairview 2001 on May 08 2007 16:22:44
     
  3. jhower

    jhower New Member

    1,208
    0
    Jul 25, 2006
    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 <img src=../Images/icons/icon_smile_pu.gif border=0 align=middle>
    2007 Flagstaff 620ST <img src=../Images/icons/icon_smile_pu.gif border=0 align=middle>
    '95 Dodge Dakota 4x2 3.9L <img src=../Images/icons/icon_smile_suv.gif border=0 align=middle>
    His <img src=../Images/icons/icon_smile_kayak.gif border=0 align=middle> & Hers <img src=../Images/icons/icon_smile_kayak.gif border=0 align=middle> Pelican kayaks
    http://community.webshots.com/user/jhower55
     
  4. shocker

    shocker New Member

    52
    0
    May 7, 2007
    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.
     
  5. jhower

    jhower New Member

    1,208
    0
    Jul 25, 2006
    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 <img src=../Images/icons/icon_smile_pu.gif border=0 align=middle>
    2007 Flagstaff 620ST <img src=../Images/icons/icon_smile_pu.gif border=0 align=middle>
    '95 Dodge Dakota 4x2 3.9L <img src=../Images/icons/icon_smile_suv.gif border=0 align=middle>
    His <img src=../Images/icons/icon_smile_kayak.gif border=0 align=middle> & Hers <img src=../Images/icons/icon_smile_kayak.gif border=0 align=middle> Pelican kayaks
    http://community.webshots.com/user/jhower55
     
  6. shocker

    shocker New Member

    52
    0
    May 7, 2007
    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.
     
  7. shocker

    shocker New Member

    52
    0
    May 7, 2007
    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
     
  8. jhower

    jhower New Member

    1,208
    0
    Jul 25, 2006
    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 <img src=../Images/icons/icon_smile_pu.gif border=0 align=middle>
    -SOLD-'89 Coleman Sun Valley <img src=../Images/icons/icon_smile_pu.gif border=0 align=middle>
    '95 Dodge Dakota 4x2 3.9L <img src=../Images/icons/icon_smile_suv.gif border=0 align=middle>
    His <img src=../Images/icons/icon_smile_kayak.gif border=0 align=middle> & Hers <img src=../Images/icons/icon_smile_kayak.gif border=0 align=middle> Pelican kayaks
    http://community.webshots.com/user/jhower55
     
  9. shocker

    shocker New Member

    52
    0
    May 7, 2007
    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.
     
  10. shocker

    shocker New Member

    52
    0
    May 7, 2007
    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
     
  11. jhower

    jhower New Member

    1,208
    0
    Jul 25, 2006
    Looks like it's coming along pretty well.


    John & Cindy in Pennsylvania
    2007 Flagstaff 620ST <img src=../Images/icons/icon_smile_pu.gif border=0 align=middle> purchased 05/07
    --------------------
    '89 Coleman Sun Valley, sold 05/07 and headed for Louisiana
    --------------------
    '95 Dodge Dakota 4x2 3.9L <img src=../Images/icons/icon_smile_suv.gif border=0 align=middle>
    His <img src=../Images/icons/icon_smile_kayak.gif border=0 align=middle> & Hers <img src=../Images/icons/icon_smile_kayak.gif border=0 align=middle> Pelican kayaks
    http://community.webshots.com/user/jhower55
     
  12. rmassing

    rmassing New Member

    180
    0
    Oct 14, 2006
    Nice Pic site. Enjoyed looking at your rebuild. Let me know if all that plywood adds alot 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
     
  13. LauraD73

    LauraD73 New Member

    12
    0
    May 29, 2007
    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.
     
  14. shocker

    shocker New Member

    52
    0
    May 7, 2007
    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.
     
  15. shocker

    shocker New Member

    52
    0
    May 7, 2007
    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
     
  16. shocker

    shocker New Member

    52
    0
    May 7, 2007
    Well it took 4 weeks but it is complete now. I am finishing the sealing today then it will be ready to go.

    The whole project was not bad to do, just time consuming. Total cost was around $350 for all parts and material. The ceiling was the hardest. Try putting up a 12'8" piece of tin over your head by your self, It was fun to say the least. I do have a few wriggles in the ceiling but it is good enough for who itÂ’s for.

    I have about 60 pictures on my web page that shows the build. I redesigned the web page to be a more dial up friendly version, since I have dial up, it is now 3 pages. Hope this helps someone out in the future.
    Complete Roof Rebuild
     
  17. Fairview 2001

    Fairview 2001 New Member

    321
    0
    Dec 27, 2002
    Looks great. I rebuilt mine with the roof off of the trailer. It made doing the ceiling easier. Fun ain't it!? You should see if Steve wants to make a hot link or archive it somehow so that you work will stay in where it can be found easily. Just a thought.

    <font color=red><center><img src=../Images/icons/icon_smile_ranger.gif border=0 align=middle> Ron & Barbara <img src=../Images/icons/icon_smile_bike.gif border=0 align=middle>
    '01 Coleman Fairview W/GlideOut <img src=../Images/icons/icon_smile_pu.gif border=0 align=middle>
    2004 GMC Sierra 1500 W/Sway Control
    3 Fantastic Boys</font id=red> <img src=../Images/icons/icon_smile_camping.gif border=0 align=middle><img src=../Images/icons/icon_smile_kayak.gif border=0 align=middle>
    Our General Store

    <font size=4>Click Here To See Our Photo Site</font id=size4></center>
     
  18. jhower

    jhower New Member

    1,208
    0
    Jul 25, 2006
    Congratulations, Shocker! The roof looks great!


    John & Cindy in Pennsylvania
    2007 Flagstaff 620ST <img src=../Images/icons/icon_smile_pu.gif border=0 align=middle> purchased 05/07
    --------------------
    '89 Coleman Sun Valley, sold 05/07 and headed for Louisiana
    --------------------
    '95 Dodge Dakota 4x2 3.9L <img src=../Images/icons/icon_smile_suv.gif border=0 align=middle>
    His <img src=../Images/icons/icon_smile_kayak.gif border=0 align=middle> & Hers <img src=../Images/icons/icon_smile_kayak.gif border=0 align=middle> Pelican kayaks
    http://community.webshots.com/user/jhower55
     
  19. austinado16

    austinado16 Proud Starcraft Owner

    129
    0
    Jun 9, 2007
    Fantastic job!!!

    Bought an '87 Starcraft Nova in February and the front roof panel and about 14" of the front side panels had turned to mush inside.

    Got away with just peeling back the metal skin and rebuilding just those areas. On the ceiling I went right over the existing 1/8" Luan with sheets of 1/8 Abitibi that's smooth gloss white on one side (it's that stuff you see in public restrooms sometimes).

    ______________________________________________
    1987 Starcraft Nova pushing a 1990 GMC Suburban.
     
  20. I have a question.

    I am going to be replacing the side pieces on my roof at the end of the season.

    Rather than use plywood, I was considering planing down some Trex so that I won't ever have to worry about it rotting (or getting infested) again. My brother seems to think that it will be too heavy, and won't have enough structural integrity.

    Any thoughts??


    Joe

    <img src=../Images/icons/icon_smile_pu.gif border=0 align=middle>'96 Rockwood Signature Series 1280
    <img src=../Images/icons/icon_smile_suv.gif border=0 align=middle>'05 Ford Freestyle
     

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