Repair

I think that "old beater" is actually a 32 1/2' 4 year old MH. ;)

Honestly it depends on how good the rest of the rig is. From your picture, your RV looks like an old beater like mine.

For me, it would not be worth the money to rip open the cab and rebuild it. I'd probably slap some Eternabond over it and call it good.

I am no expert on this, but if water got inside limitedly and you are able to dry everything out well, then I would drill a hole at each end of the crack to prevent it from growing, then fiberglass over it, then add a nice creative piece of trim of some sort across the entire front to hide the patch work so the rig looks nice again.

This is the front/bottom of the cabover canteliever, right? Not the part next to the roof?

If so, assuming the construction is similar to my '98 Coachmen, you can get access to the other side comparatively easily by popping a few fabric buttons off the lower buckboard sort of panel between the bunk area and the front wall/ceiling of the cabover, and then removing the screws underneath the buttons. This buckboard then comes off. Underneath is probably some fiberglass and a sort of wooden cage framework, with the Filon and some thin plywood or something (which may have decomposed) backing it.

I've attempted to repair a couple of (smaller) cracks in mine by epoxying a couple layers of fiberglass cloth to the back of the Filon. In this case it looks like the crack extends all the way to the edge, so you'd probably need to remove the aluminum corner moulding channel and the edge seam underneath the bunk to get access to the back. I filled the front of the crack on mine with thickened epoxy (with a white collodion filler), which kind of sort of blends in if one doesn't scrutinize super closely. I still need to sand things a bit smoother. It does look like it will work for me, at least for awhile. Time will tell.

I also didn't like the cage-like framework Coachmen used, and constructed a replacement frame more akin to barrel staves—a bunch of thin slats butted together over a set of plywood formers, sort of like a wooden boat construction. I put a layer of fiberglass on the front and back of this to tie the slats together. It was a good bit of work to construct, but the result is sturdy but lightweight. (It's not the prettiest construction, but that's OK since it's hidden.)

If the crack has been around for awhile, there's a good chance of at least a little rot etc. to take care of. Hopefully the angle is such that not much water tends to get in and collect.

Currently I am out of town,will return on Sunday and take more pictures and will post it.I am wondering how does this happen.My RV is parked on my driveway for last several months and I just noticed this few weeks ago.No hit or accident.Can this happen just being parked for several months.I have only 15 thousand miles on it and it is 2011 model.

Put up a couple more pics. and we can give better advice. I would worry that there is water damage underneath.

Yes you can sand down, feather edges, repair with fiberglass and re-paint. I don't know how good you are with that stuff but you need to have decent skills.

If there is damage that says rebuild, that could range from $8K to $10K. At least that is the estimate I heard when I asked about cost to rebuild the cabover on mine.

Jose

I am not assuming anything, but a sort of close look at the pic, to me suggests that this rip isn't new. In fact, by the look of the trim on the side, it maybe hasn't had much tlc in the past. Did you just buy this rig? Not that it really matters, but that pic looks some ugly to me and just putting some tape over it and sanding and painting isn't going to make this whole again.

Could you fix it? Sure, as has been observed, if you have a place to do it and the skills. That skin has to come off right to the seam on the roof and then all the way under the cab. You'll need to address any wood rot, as I had mentioned. That means tearing out and replacing and damaged wood and insulation. Plus, if there is any rot under the skin, I'd bet that it is in the inside as well, in the bunk area. If you don't do this yourself then it's an RV shop then you are talking a whole bunch of money.

If you can find a handyman that knows woodworking to help you? That's be a good way to consider going. It's not rocket science, but if you don't do it right, that will just fall apart.


Gary Haupt

Might want to use Marine Tex. I is white already. Apply after sanding/prep. then use a ridgid plastic film taped over it to contour and shape. Remove the plastic when cured and sanding/shaping will be minimal

can a piece of thin fiberglass be put on over that area using epoxy or similar? Probably won't look worse than slapping fiberglass cloth/resin on it.
bumpy

Here is one online source for filon. The shipping cost is fairly expensive. Perhaps a cheaper option would be buying the material from a local RV shop.
Whether you can do it or not depends on how handy you are. It's a pretty straight forward process, once you get into it. The extent of the repair is going to depend on how much damage has been done by that open wound in the cabover. How long has it been cracked ?