Forum Discussion

Phlamber's avatar
Phlamber
Explorer
Mar 15, 2017

Aluminum Roof Repair on '78 Pace Arrow

So, we have a 1978 Fleetwood Pace Arrow with an Aluminum roof.
This thing has seen better days and we're doing what we can for it.
Currently we are fixing the roof.
We have removed most of the old roof coating using Jasco paint stripper (wonderful stuff!) with a paint scraper and sandpaper. It looks as though someone used Bondo(?) in the past to make the roof flatter.
The leaks have caused the thin layer of wood that sits between the roof and the styrofoam insulation in the ceiling to all but rot away. As well the steel beams that support the roof and ceiling are rather rusty.
Now, when this thing was put together they didn't leave much overlap on the sides of the roof. So, whatever?we do to it we have to keep that in mind.
The roof is dented in many spots. In fact, it says down severely right around the front vent/skylight before sloping upwards again sharply to where the vent actually sits/attaches.
I personally think that we should unscrew the sides of the roof and remove the old rotted wood and replace it with 1/8" plexiglass, or something similar. My boyfriend thinks that we should use something like Bondo and just flatten the outside of the roof.
All this would precede us painting the new elastomeric layer on, of course.
We don't have much money. But, we both recognize that spending the right amount of time and money now could save us a great deal of money and hassle later on down the road.
(I will post pictures of the roof as soon as I can get decent lighting to do so in.)
  • I'm with you on removing the roof to fix what is underneath. Any sag you see is some sort of structural problem that needs to be fixed. Most likely something rotted away. Older coaches like that had a lot of wood in the roof. We had both a "Leisure Lodge" and an old Winnebago from that time frame and both required a lot of roof rebuilding. The good news is that you are not really talking about a lot of materials and a cheap blue tarp from Harbor Freight will let you work on it at your leisure. The minimal material cost will be far outweighed by the time you spend doing it. Just take your time, don't get in a hurry and do it right the first time. Fix it right and you won't have to deal with it again. You'll find lots of help here. Post what you find (you are not going to really know what's up until you get the roof opened up) and you'll get lots of help!
  • I would remove the rotted wood for sure, then I would take a wire wheel and see to what extent the framing is rusted. If it's just surface rust no big deal, deep embedded rust is a problem. If the rot material is taken care of with good wood and it is flat & straight, you may be able to get a rubber mallet and "pound" the aluminum back into shape and then seal. Just my .02 without seeing it. :)
  • I had a 78 Itasca. The previous owner had installed CB Antennas and used the aluminium roof as the ground connection. Over time, due to 'Electrolysis' it developed hundreds of tiny holes all over the roof metal. I cleaned it very well and used a paint roller to spread the 'Elastomeric' white Roof coating on in 5 coats. Worked very well for years.
  • You do understand you have a Motorhome that is worth less than $1000. ANY money spent on it will NOT increase its value. It is just money down the drain when you decide to get rid of it. As long as you understand this, then you can go ahead and fix things when you realize you will never recover the money spent. Doug