Hi all, New to the forum. I purchased a 2002 Arctic Fox 990 from my parents recently (they were first owners) and there is front delamination. The camper was covered by like 1,000 tarps because dads like tarps. After I purchased it I discovered the delam issues. It's not a pretty sight, but I am confident it isn't a result of prolonged water intrusion because it was always covered. We renegotiated the deal after I discovered the issue to our mutual satisfaction. Where so I purchase the filon material, and is there a cheaper alternative? Should I cut a new seam or put on a front sheet to the base of the camper? Minimally invasive is what I am hoping for. I used to enjoy projects like this, but this doesn't look super fun. I am preparing to do an off-grid year exploring America and possibly doing the whole Youtube thing, so I would like it to be sound and aesthetic for when I depart. Thanks in advance for your feedback, I appreciate it.

Delam is almost always caused by water intrusion of some sort. Pictures of the situation will helps us comment. I had to perform extensive repairs to a filon sided camper years ago and as you allude, it is not fun. It is not that it can't be done, but it might end up to be more than you think.I am not trying to sound pessimistic but there are folks here who do as a hobby of sorts and anticipate it as a challenge. If you opt to take on this repair, my advice is to see it through, keep a positive attitude, it can get discouraging if new surprises appear. In the end it will be something to be proud of. I did similar on a previous TC and almost gave up but I got 'er done. I will not do it again.

So much depends on what you find if and when you actually take the existing filon off. Sometimes the delam occurs from the overhead seam leaking. Water comes in and wets the surface, then the filon separates from the plywood.On the other hand, you could seal it up as best you can, and not attempt long and difficult repairs.

When I was looking for a newer truck camper I came across tons of campers that I liked except for the fact that about 90% had delamination problems. One of the campers was exactly what we wanted but had front delam around the over hang window. I went to the local RV repair shop and started asking about how you fix and since it was a small area around the window, what would it cost to have them repair it. The guy in charge of the repair area said, if it has delamination, we charge $2000.00 just to start and then its hourly after that. He said they would fix it but its expensive and if any water get in its gonna just delaminate again, he suggested to me, if its not horrible live with it and just use the camper and enjoy it.... That was my experience with delamination and I passed. You tube has some vids on repairing delamination thats where I would check first if i was determined to try to fix it. Keeping all the seams and around windows sealed is really important to keep delamination at bay

Two thoughts. First delam can also occur when things are tarped too heavily and that is one of the reasons the covers you purchase are vented. They really are not supposed to be air tight. When I tarp our truck camper, I only bring the tarp part way down the sides and we don't wrap it. On our fifth wheel we use a vented cover for that purpose. Ideally they have to breathe.Working professionally on RVs for decades I can tell you delam repair borders on the impossible. There is an adhesive specifically designed to adhere it back into place, but you have to be able to pour it into between the filon and the backer and then you have to be able to clamp it for 24 hours. For small bubbles you can drill a small hole and shoot the glue in ( I used a large hypodermic needle, but again it is a total B and not for the faint of heart.

Wow, never expected these many responses so quickly. The picture function dictates that we host the on another site like photobucket? is this for real? '98 internet called.lolMy father had his truck bed damaged and shifted minor in an accident and he thinks the bed is warped which is what allowed the camper to leak, even though he only mounted it 5-6 times and used it that much. It's like brand new everywhere else.

How do I repair delamination filon? Arctic Fox 990

Downwindtracke1
Explorer
Oct 08, 2018
It's just fiberglass and polyester resin with a thin gelcoat, you are dealing with. Once the air is allowed out, it should flex.

Most of the time will be used in the mold/strongbacks making which once your two templates are made, they can be done in a basement. A couple of weeks of evening with your new spindle sander. Wear a dust mask. Ask System Three out of Portland which epoxies they recommend. An old eggbeater hand drill is the perfect tool for drilling the tiny holes for the injection. Big agricultural syringes might be harder to come by.

The repair can easily be done on a weekend, and covered by, get this, a tarp, chuckle.

My neighbor has done a couple of delams under windows on his '08 Fleetwood toy hauler. And has a couple more to do.

We have ORV travel trailer which had 1/32" or less checkerplate on the nose, which I dented. I replaced it with 1/16", and framing behind it. 2 years in ! I had a hard time finding a shop to roll 1/8" so I swapped the 1/8" for 1/16" and got a free roll.

My hunting camper is a stick and tin.

Nash might still be using the mold , so you might ask them for parts. They are just south and east of you in Le Grande . That would do a much nicer job, but it would be more work.
presh223
Explorer
Oct 08, 2018
Downwindtracker2 wrote:
Boat owners deal with delamination a fair bit. Polyester resin doesn't stick to wet wood. West System has vids on it. Watch them. I like using epoxy for repairs and building. Inject epoxy and clamp, simple.

I would rate that as an easy fix,pulling the window allows you to clamp. A male and female molds, and very serious strong backs. I would build them out of 3/4" plywood and 1/2" RediRod. A jig saw and a drum sander would your friends as you make 14? identical curved plywood edges for your female mold. You'll need fewer male. Look at the mold stations on cedar strip canoes .

Not very difficult but certainly time consuming.

While you're at it, pull all the windows and corners and seal with Proflex or Stkaflex.

The problem is the filon had hardened significantly and the bubbles are not maliable at all. I think before I go trying to salvage this piece, it may be easier to just sheet it with one of those sheets of diamond plate. I just don't know where to stop it. I think I would p opt to create a new seam just below the curve under the window to not have to mess with all of that because all though it has sagged down there a tiny bit, I hope it stays intact. But if you're already embarking on the fix I presume you should do it right. I am in Seattle, and don't have good cover from rain. So I guess gotta find a garage to rent or something. How many hours you estimate this project to take? 20-30?
Downwindtracke1
Explorer
Oct 08, 2018
Boat owners deal with delamination a fair bit. Polyester resin doesn't stick to wet wood. West System has vids on it. Watch them. I like using epoxy for repairs and building. Inject epoxy and clamp, simple.

I would rate that as an easy fix,pulling the window allows you to clamp. A male and female molds, and very serious strong backs. I would build them out of 3/4" plywood and 1/2" RediRod. A jig saw and a drum sander would your friends as you make 14? identical curved plywood edges for your female mold. You'll need fewer male. Look at the mold stations on cedar strip canoes .

Not very difficult but certainly time consuming.

While you're at it, pull all the windows and corners and seal with Proflex or Stkaflex.
Kayteg1
Explorer II
Oct 08, 2018
ardvark wrote:
I am also familiar with their product having used it. The video is fine as long as you bear in mind it shows repair in one of the easiest locations at a window. What I found is being able to clamp things while the glue dries is crucial and in many locations can be really difficult.

It also shows epoxy applied in mild weather.
As much as I love epoxy for such repairs, using it in triple digits temperatures gives you about 5 minutes work time before it turns into jello.
Not enough to do any serious job.
They also have long-reach clamp that I have never seen at tool places.
presh223
Explorer
Oct 08, 2018
presh223
Explorer
Oct 08, 2018
presh223 wrote:
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Sorry still have trouble loading pics, but yes this is where it's at. My father said the same thing like don't worry about it, but it's the face of the camper and just looks like ****. I was thinking about removing the window and possibly screwing in a sheet of aluminum, diamond plating just to hide the issues and make it more aesthetic. Ya, it will look weird, but atleast it won't be ugly. But I always hesitate screwing anything into the body of that camper, don't even know where the framing studs are located.
presh223
Explorer
Oct 08, 2018
I am trying to upload pics here with the use of third parties and with the help of one of the comment responders. When I preview the message it shows up, and when I post it shows what you are all seeing. I can't be this inept.
presh223
Explorer
Oct 08, 2018
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presh223
Explorer
Oct 08, 2018
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Grit_dog
Navigator
Oct 07, 2018
Our 03 has the same typical? front cap delam, around the front window.
It was from either the clearance lights or window leaking I presume and was well sealed wen we bought it (goobered up though).
I pulled the window out and nothing was/is rotten, but the fiberglass is too stiff to glue back in place and cant realistically build a jig easily to put significant pressure on it.
IMO, not worth the time or effort, it's only cosmetic in this case.