Jayco Center Seam Rebuild

mredden

Member
Sep 21, 2006
10
When we opened up our 1998 Jayco 12SO after this winter we discovered the center seam of the roof leaked near the back staining the canvas on the bunk on that end.

We saw a gap in the caulk of the center seam by the low spot in the roof. Snow load here in MA must've opened it up. My wife attempted to make repairs by cleaning off the old caulk and reapplying some new, but it still leaked.

I decided it was time to try to make a more permanent fix. Last night I started removing the metal strip that runs down the center of the roof covering the seam.

I have a plan to clean everything off, cover the seam in the aluminum with a 4" strip of Eternabond RV roof repair material. Then reapply the metal strip with new stainless screws and a new putty tape, or a new butyl tape, finally caulking the edges of the seam with 3M 5200.

Is this the correct way to make this fix? Should I use putty tape or butyl tape? The seam originally had putty tape under the metal.
 

Tekboy46

Super Active Member
Aug 15, 2007
979
Central Oklahoma
Sounds like you have a sound plan. Lots of members swear by the 5200 and should chime in with their thoughts. That being said, your keywords Stainless, Eternabond and 5200 should equal a bulletproof seam and roof. If you proceed, post how things go on the fix.

1979 Starcraft Venture
1996 Ford F150 TV
 

mredden

Member
Sep 21, 2006
10
I followed my proposed plan and everything worked out fine.

I did find a few of the screws holding down the aluminum were screwed into wood that was a little soft, but I shoved some wooden match sticks and some exterior wood glue down the holes to make the new screws hold a little better.

I did use stainless steels screws one size bigger than what was in there. I could only find sheet metal screws in SS that were the proper length. I used new butyl tape and finished off the seam with a new vinyl insert.

I caulked the center seam and the edge seams with 3M 5200 after scraping up any remnants of old caulk.

The rebuilt seam made it through a few thunderstorms without leaking last week while camping near Lake George, NY.
 

BigEasyCampr

Active Member
Apr 12, 2005
130
I went throught the very same exersise this past weekend. This coming weekend I will be setting the PUP up and let the sprinkler run on it to make pretend rain. If yours worked, i'm confident that we won't have any problems.

Harry
'05 Chevy Silverado 1500 Ext. Cab <img src=../Images/icons/icon_smile_suv.gif border=0 align=middle alt="Tow Vehicle">
'99 Jayco Eagle 12ST<img src=../Images/icons/icon_smile_pu.gif border=0 align=middle alt="PopUp">
 

LocalMan Dan

New Member
Aug 22, 2018
4
You guys I know you may be long retired by now but just in case! I am about to follow your lead on this exact repair, I live in the sticks and don't have much support, are you still happy with what you did?
Dan strip2.jpg strip.jpg
 

CamperChrissy

Active Member
Nov 25, 2016
656
Chicago suburbs
I've also did this repair on my Jayco last spring and it has held up great! I removed everything, cleaned it all up good. Put down new putty strip. Then screwed the metal track back down with new screws. Inserted new vinyl strip in the metal track. Caulked around the edges. I got the putty strip, vinyl strip, and caulk at my local Jayco dealer and it was all priced well (I compared with online prices). The hardest part was removing the old caulk (well, the parts that were still adhering...). Good luck!
 

cornstalk

Member
Oct 22, 2019
33
My pop up leaks at a couple places along the center strip. Are the two repair methods described above the best way to fix the leaks?
What should I use to remove the old tape and caulking? I don't want to gouge the roof. I'll post photos so you can see what I'm dealing with. Thanks.
 

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johneliot

Active Member
Jan 1, 2022
506
Chico, CA
Mine is not leaking so I just ran dicor along each side of the metal strip and replaced the plastic strip along the length that covers the screws. If I needed to do it again, I would also run 4in wide eternabond the length of the seam. I would not put the strip back on because why put screws through the eternabond. It would just allow another place for water to seep in.
 
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cornstalk

Member
Oct 22, 2019
33
Mine is not leaking so I just ran dicor along each side of the metal strip and replaced the plastic strip along the lenth the covers the screws. If I needed to do it again, I would also run 4in wide eternabond the length of the seam. I would not put the strip back on because why put screws through the eternabond. It would just allow another place for water to seep in.
Thanks John. I need to start removing the center strip materials so I better understand the explanations. I didn't even know there was metal in the strip.
 

johneliot

Active Member
Jan 1, 2022
506
Chico, CA
You can see the dicor along the edge and the white plastic strip down the middle that I replaced. If I had taken the strip off, then the etrnabond along the front and back would have been one piece and then I would have ran it all along the seam down the middle. In retrospect I probably should have done it that way. There was no leaking along that strip except on the ends so that’s where I taped. Looking at your roof, that’s how I would handle it. Make sure if you go the eternabond route you clean real well and then use alcohol to clean the area some more so the tape adheres well.
1680364093879.jpeg
 
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johneliot

Active Member
Jan 1, 2022
506
Chico, CA
I would use a plastic putty knife. The putty tape under the strip should come off easily. The tape will be more difficult. Use mineral spirits to help with the tape and residue and just take it slow and don’t be in a hurry.
 

cornstalk

Member
Oct 22, 2019
33
I would use a plastic putty knife. The putty tape under the strip should come off easily. The tape will be more difficult. Use mineral spirits to help with the tape and residue and just take it slow and don’t be in a hurry.
Thank you so much. This really helps. I just bought it and it's my first popup. I have many questions.

My popup has the same bumper as yours, but mine is separating on one side. I'll get a better pic for that. Also, the bottom of the door is starting to rot. Again, I'll get more pics.

I just bought a big tarp and rope to prevent any further water infiltration. We are having high winds, rain & hail. The weather should clear up Tuesday or Wednesday.

Also, when cranking up the roof, sometimes there is a super loud popping sound as it approaches full height. Loud enough to scare me.

Thanks!
 

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cornstalk

Member
Oct 22, 2019
33
Thanks. I know that stuff. I have a bunch of it behind the front seat of my truck. I bought it for the topper on my truck. Still have to put it on.
If you’re wanting to keep the factory look, this is the stuff that covers the screws inside the trim.

 

johneliot

Active Member
Jan 1, 2022
506
Chico, CA
It’s easy to see why Jayco didn’t put spares on the bumper. The metal is thin and the welds are crappy. Without seeing it I’d guess you’ll need to reweld it. You’ll have to take the door off and rebuild it. I did that on the ‘95 I had. Not too difficult. I kept the outside and inside and was able to rebuild the inner structure. Looks like you have surge brakes.
 
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cornstalk

Member
Oct 22, 2019
33
The popup came with every manual and the original invoice. I'm looking at one manual for the Surge Brake System. (Atwood Mobile Products). I know nothing about mechanical stuff. Maybe I'm in over my head. Will I be using that brake thing? My truck came with a trailer brake component. It always has a light on.
 

johneliot

Active Member
Jan 1, 2022
506
Chico, CA
Surge brakes work just like regular brakes. That cap is for brake fluid. How well they work depends on how well they were maintained by the PO. As the tow vehicle slows down the trailer hitch pushes against the ball and a piston pushes fluid through the system and applies the brakes. If everything is functioning as it should, they work fine. The trailer brake in your truck is for electric brakes, has nothing to do with surge brakes.
 
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Camping Kat

Member
Apr 16, 2023
26
I just started mine today. There must have been at least 3 different types of caulk on the center seam. 1996 Jayco 1007 Jay Series PXL_20230510_205053560.jpg PXL_20230510_230028075.jpg almost done cleaning
 




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