Problem with Rubber Roof

I have a 2015 36-foot Crossroads Rushmore 5th-wheel purchased in December 2014 so it was 6 months out of warranty when the problem occurred.

While driving from Glyndon, MN to Bismarck, ND on 6/25/2016, and from Bismarck, ND to Medora, ND on 6/26/2016, we were driving west into a dead-on head wind of 25 mph with gusts to 40 or 45 mph. This was a total of about 350 miles as the strong winds were present all day, both days.

After positioning the trailer at the Medora Campgrounds campsite, I noticed a ripple in the rubber roof membrane about 2-feet to the rear of the joint at the front fiberglass cap.

Also, there was a gap in the caulking almost the entire length of the joint between the fiberglass cap and the roof membrane. The membrane had moved toward the rear about 3/4-inch and taken half of the caulking with it, leaving a gap in the caulking. Note: The edge of the membrane never came out from under the fiberglass cap.

I was able to work the ripple forward and back under the fiberglass cap, and mostly closed-up the gap in the caulking, but it needed sealant applied as the joint was no longer water-tight. I found a local RV tech who installed a patch over the gap which we hoped would get us home where a more complete repair could be done.

After we arrived home, I noted that the ripples had once again appeared plus there was an indication that the membrane had started to pull out from the left and right side rain gutters as well. The rubber membrane was no longer glued to the plywood for at least the first 12 feet back from the fiberglass cap, maybe even further back.

My question is what options should be possible for fixing the roof? My expectation was that the rubber membrane could be re-glued to the plywood since it is still intact with no cuts or tears; however, my dealer tells me that the only fix that will prevent future problems is to completely replace the roof (rubber membrane) to the tune of $9000. The service manager says that the existing membrane has been stretched by the wind, and it will never lay down correctly again.

Has anyone gone thru a similar problem, and if so, how was it repaired?

13 Replies

BruceMc
Explorer III
Aug 18, 2016
We've seen a couple of fivers on the freeway with billowing rubber roofs. Apparently there's quite a vacuum where the air flows over the front cap.

I think you are wise to replace the rubber with something a lot more durable in those conditions.

We had a rubber roof on our 2000 four winds motorhome and I often wondered if it would do the same thing. The front cap is much smaller on a motorhome that it is on the tall fivers, so apparently it is not a problem.

Our new motorhome has a fiberglass roof, so we no longer are concerned with issues now regarding a rubber roof.
CarnationSailor
Nomad
Aug 18, 2016
Auto insurance company has agreed to pay for a new roof. They were willing to pay $9000 for a new rubber roof, but I am going with a Rhino Roof which will cost them about $6500 and be guaranteed for 20 years.
Lynnmor
Explorer
Jul 30, 2016
I would call Crossroads and ask if they might want to fix it since they didn't build it correctly in the first place. Yes, the warranty has expired, but give them a chance to prove that they just don't care. Maybe they could do a factory repair at a sensible price. If they offer no help, then you know what type of company you are dealing with.
Dave_H_M
Explorer II
Jul 30, 2016
agree that the Stealer is probably trying for deep pockets.

That roof has to be reglued to the underlayment properly and then the edges attached and caulked properly.
westend
Explorer
Jul 30, 2016
I'd suggest to remove the edge trim and any front cap trim, also any vents in the way, fold back the rubber membrane to securely installed membrane, and glue it back down. Even if a new membrane is required, the price of new EPDM is less than a few hundred dollars. $9K for a new roof membrane installed is exceptionally high, almost in gypsy territory.

If you can't DIY, visit a commercial flat roof installer. I'd bet price will be less than a third of that initial estimate.
belairbrian
Explorer
Jul 30, 2016
Seems that if the remainder of the roof is still attached properly, they could either glue back down the forward part or replace the seal the seam with eternabond. It still wont' be cheap as to do it properly will require removing and replacing trim, vents, etc.
Charlie_D_
Explorer
Jul 29, 2016
DownTheAvenue wrote:
Sounds like the glue holding the membrane to the roof underlayment has been compromised. Without the glue holding the membrane to the underlayment, any repairs will be temporary at best, and ultimately, the membrane will work loose again.

Or never glued down originally. I would repair it as suggested with Eternabond but I would also glue/reglue the membrane. Last year I saw a brand new first time out camper in the parking lot of a Buckee's east of Houston with the wife and son trying to put that same area down with Gorilla tape so they could continue their trip. It did not look like it had been glued down and came out from under the seam running across between the membrane and front cap. OP-no harm in calling the manufacturer and explaining you problem. Maybe they will step up or give you ideas on how to repair.
CarnationSailor
Nomad
Jul 29, 2016
DownTheAvenue wrote:
Sounds like the glue holding the membrane to the roof underlayment has been compromised. Without the glue holding the membrane to the underlayment, any repairs will be temporary at best, and ultimately, the membrane will work loose again.

I have to wonder if the OP had washed the roof with unapproved solutions causing the glue to dissolve. This is a known problem and is well documented. The membrane manufacturer probably has a list of approved solutions in their owner's manuals.

You can stop wondering.

I only used Dicor cleaner and Dicor UV protectant.
DownTheAvenue
Explorer
Jul 29, 2016
Sounds like the glue holding the membrane to the roof underlayment has been compromised. Without the glue holding the membrane to the underlayment, any repairs will be temporary at best, and ultimately, the membrane will work loose again.

I have to wonder if the OP had washed the roof with unapproved solutions causing the glue to dissolve. This is a known problem and is well documented. The membrane manufacturer probably has a list of approved solutions in their owner's manuals.
Dr_Quick
Explorer II
Jul 29, 2016
I disagree with RV place, as the only solution is to replace the whole roof.
On my previous trailer I had on old leak at the front road side corner. My repair worked fine and all the rest of the time that I had the trailer saw no sign of rubber coming loose. The roof wood was damaged so I had to replace it. I took off the front trim strip, then removed as much side trim at roof to siding as necessary. I cut the side trim with a hack saw being careful not to cut into the rubber roof. I pealed back the membrane. Then replaced bad roof wood. Reinstalled roof membrane, I put glue on both the wood deck and back side of the membrane. Installed trim strips with new putty take and used Dicor to seal where it was used before. Since side strip is usually a gutter you will have to seal joint where cut.
Since you have a fiberglass cap that sounds like it may not be secured to deck, you may have to screw it down. Or use an aluminum trim strip between rubber roof and fiberglass cap. Just be sure to use putty tape under trim strip at joint between roof and fiberglass cap. Then seal both sides of strip and screw heads with Dicor.
If you need more info PM me