Forum Discussion

hemifish69's avatar
hemifish69
Explorer
Oct 14, 2014

serious modifications

I'm posting here to cast as wide net as possible. 

Bought a 2005 surveyor hybrid for 6k, because that was my financial comfort level. 

All mechanical/electrical items are fine, but so far I've had to fabricate an aluminum replacement for my bunk end door, dig out a soft spot between the bathroom vent and the side wall and replace with foam and fiberglass,  and paint entire roof with the white rubberized coating to seal the aging rubber membrane. 
The luan/foam sandwich that my roof is worries me. No low spots, but I'm entertaining ideas of spanning the width of my roof with more square tube aluminum and fabbing another roof over the present one, and extending my vents/etc to protrude above it.
Reasons?  I heard the top luan make crunchy noises as I applied my paint. The trailer is healthy to all other appearances,  and the tap test inside says the roof is sound. But my labor is cheap,  and I'm not ready to try and flip this on some unsuspecting camper buyer. I'd rather hold on to it and over build it like the bunk end door.
I'm a former airline mech. I could go full airstream style on the roof, but I'm looking for suggestions before I go crazy. This could be done in stages, remain weatherproof during, and become very snow - load resistant.  It would also pay for itself if I didn't have to pay storage to avoid snow exposure. 
Just wondering if it's something anyone has attempted.
  • I don't know about you're roof but my Jayco has 1/8in luan board with aluminum reinforcement and Styrofoam in between and another layer of 1/8 in. luan on the bottom. If yours has thicker luan it will hold more weight. Why don't they just call it plywood? Any cracking sound is the luan flexing with can't be good for it. When you turn fully lift your feet so you don't damage the rubber layer.
  • I weigh around 155 and walk on my roof at least twice a year to clean the solar panel. No odd noises, and no feeling of softness. If the odd noise only happens in a particular spot I'd wonder about damage...
  • I typed this on a phone, so I may have omitted some detail. When I had to get near the middle, I used 2x4 and plywood to even out my weight and still crawled. The crunchy happens with a fingertip or palm when inspecting the roof. I would never have trusted my weight standing (230 lbs)
  • Roofs are only walkable to a certain weight. When I weighed 240 lb. I asked Jayco if I could get on my roof to clean it they said yeah go ahead when I hit 260 I asked again and they told me to put a piece of plywood down. Check with the manufacturer.
  • Crunchy noises? My last trailer was an '03 that we had for 10 years. I never covered it and parked it outside in all weather including snow. My roof never crunched. Not all roofs are made to be walkable. Jayco's are. You might send an e-mail to Forest River and see what kind of info they can give you about that roof.
  • that model is considered lightweight and as such has lighter materials used in the construction process. The roof is prob. 1/4 plywood with a sandwich of styrofoam for insulation and is not what would be considered a full walk-on roof. The crunch noises are normal. You take a 180-200 lb man and they try to walk on a roof made out of that material and you risk damage to the roof. Suggest putting a small sheet of plywood down to evenly distribute your weight if you are working on the roof, or rent some scaffolding. Unless roof has water damage there is no need to rebuild anything
  • hemifish69 wrote:
     

    The luan/foam sandwich that my roof is worries me. No low spots, but I'm entertaining ideas of spanning the width of my roof with more square tube aluminum and fabbing another roof over the present one, and extending my vents/etc to protrude above it.
    Reasons?  I heard the top luan make crunchy noises as I applied my paint.


    My roof made the same noises from day one. I think its just the nature of the construction. If you have it sealed up nicely, I wouldn't worry about it. If you look at the per square foot load of snow, its a lot less than you standing on it. Plus adding a second roof is going to eat up a lot of your cargo carrying capacity.

    Not sure the time & cost is going to be worth it.
  • hemifish69 wrote:
    It would also pay for itself if I didn't have to pay storage to avoid snow exposure. 
    Just wondering if it's something anyone has attempted.


    I have parked my RVs with snow exposure for 20 years, what is your worry
    bumpy