Pop Up Camper roof repair/rebuild

joerg68 wrote:
re. rebuilding the roof:

A friend with an old palomino built a one-off negative jig/mold and had a new one-piece roof laminated by a local company that makes all sorts of fiberglass parts. I helped remove the old roof and install the new one. I am not sure if that is a viable approach for you though. The friend is quite persuasive and he got that company (they normally make truck fenders and the like) to make him that roof. It may have also helped that the company was in the truck camper manufacturing business until some years ago, and they made camper tops until recently

It was not an easy thing to do as he had to build the jig/mold, truck it over to the manufacturer, and pick up the finished part. And then it was keeping your fingers crossed if the new roof would actually fit. I am not sure if that approach would save much money/work/nerves vs. your Hallmark quote...

Another popup owner that I know stripped just about anything from underneath the roof and replaced all structural parts as he kept going - he retained the outer skin and corner moldings, but not much more. Either way, fixing a rotted out popup roof is a lot of work, and not of the nice kind.

Sureley rebuilding the roof alltogether is better than patching up a badly rotten one.

Thanks for the suggestion but probably not an option. Palomino will sell me a roof but with shipping that also is not an option. I live in a small town, Homer, Alaska, and there are no companies near me that do any type of fabricating! I see the light at the end of the tunnel with removing the aluminum skin off the roof lid . . . . but I have not tried to put it back together!