Hello, I am about to undertake the ultimate in roof repairs and open the biggest can of worms. I recently purchased a used 2008 Fleetwood Avalon. Other than the roof, it is in immaculate condition. Last weekend I replaced the A/C Gasket, suspecting the source of some rippled ceiling panels, which was about 1/8" thick, far smaller than the uncompressed 1" new gasket. There were also two hairline cracks that originated from the corners of the 14 cut-out for the A/C. When I removed the A/C I realized the extent of the damage. The Luan plywood essentially exploded. The only thing holding the roof together was the lower bracket for the A/C and the A/C itself. When I went back into the Campler," I started feeling the roof and realized that that ¾ of the roof has some delamination. In addition, I noticed some discolouration at the front of Trailer on the canvas. Again upon closer inspection the front board is also, I suspect rotten. After reviewing many posts on this site and others, I have yet to find a total, How to rebuild your Filon Roof." So I will attempt to document my progress. I have taken a week off to effect this project. Research: After realizing there are several difficult phases that needed to be completed I began researching how-tos for each phase. As I see it now the distinct phases are (all phases do not represent an equal degree of difficulty): 1. Finding a space large enough to make the repairs; 2. Finding better or the correct materials; 3. A/C removal; 4. Canvas Removal; 5. Roof Removal; 6. Roof Interior guts removal (foam/luan); 7. Lamination of filon, foam, plywood, and vinyl; 8. Roof installation; 9. Canvas installation; 10. A/C installation; and, 11. Drinking Beer. BTW, please chime in if you have suggestions. 1. Finding a space large enough to make the repairs. After measuring the Campler and my two car garage (2 doors) it appears that it will just fit...at least the roof should allow me to close the door fully. This is a good start since this repair will probably take much longer than I anticipate. Also I clearly need some way to remove the uncovered trailer from the environment. I could cover but I would rather get it all out of the rain. However, the trailer will not fit and according to my calculations. About two feet of the tongue will remain sticking out. My intention is to lower the door to the tongue and accept door being open 2 feet. Also the Campler should clear the door opening by about 1 Inch either side. Getting it in the garage will be a test of my marriage as my wife and I attempt to back into the garage. We will be using walky-talkies. 2. Finding better or the correct materials. I have been doing a lot of research on materials. I dont really care about expense if the end product is done right. Realizing that the interior of the roof is made of Styrofoam and Luan reinforces the idea that profits are the main motivator of the RV industry. My intent, and again comments welcome, is to: 1. Remove all the guts and replace with Foam board insulation, once I figure out the thickness required. 2. Replace the Luan with Hardwood Underlayment Plywood http://www.lowes.com/pd_520357-53547-520357___?productId=50124674&pl=1&Ntt=plywood. 3. Glue the entire thing together with Loctite PL Premium. 4. Apply Vinyl wall-covering to the Plywood 5. Replace the front and possibly the rear panels with wood instead of plywood, though This may not work as getting an 8 board to remain straight may be asking for problems. 6. And lastly reattach the hardware and lights to the roof using pop rivets. Next A/C Removal.