Oh boy. We're in a mess. Roof rebuild FAIL.
My parents gave us their pop up. The roof was completely rotted inside due to a leak. DH claimed he could rebuild it. He was able to get all of the rotted wood and foam out. What looked like success h...
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I guess it's a little late, but here is my experience.
Our 1st trailer was a popup with a roof very similar to yours, also very leaky. I removed all the inside liner & foam insulation & cleaned the underside of the aluminum thoroughly. Then, using construction adhesive (PL400), glued steel hat track to the underside of the aluminum across the roof every 24". (hat track is a light weight but strong channel, 1" thick used in framing commercial drywall ceilings). Extrude polystyrene board was then glued to the aluminum between the hat track with foam board adhesive. Finally I glued some 1/8" hardboard with a decorative vinyl coating on 1 side to the underside of the hat track, again using construction adhesive.
The seam down the center of the roof was the source of the leak. After the roof was rebuilt I thoroughly cleaned it & used clear caulking to seal it.
The roof was very rigid & was still in excellent condition when we sold it several years later
Our 1st trailer was a popup with a roof very similar to yours, also very leaky. I removed all the inside liner & foam insulation & cleaned the underside of the aluminum thoroughly. Then, using construction adhesive (PL400), glued steel hat track to the underside of the aluminum across the roof every 24". (hat track is a light weight but strong channel, 1" thick used in framing commercial drywall ceilings). Extrude polystyrene board was then glued to the aluminum between the hat track with foam board adhesive. Finally I glued some 1/8" hardboard with a decorative vinyl coating on 1 side to the underside of the hat track, again using construction adhesive.
The seam down the center of the roof was the source of the leak. After the roof was rebuilt I thoroughly cleaned it & used clear caulking to seal it.
The roof was very rigid & was still in excellent condition when we sold it several years later
