Hybrid Bunk Repair - New Material

[Valleybull]

I have recently completed a repair on the front bunk for my 2007 Kodiak Hybrid 23TT. I was finding that the lower seam on the bunk end was letting water seep in between the fiberglass and the aluminum channel. Unfortunately, inside the fiberglass is the cheap and super absorbent meranty board, which was rotten. I struggled to find a good material to use as a replacement that would not absorb water. I spoke to a friend in the sign business, and he put me on to Alumapanel. It is a 1/8" or 3/32" panel that is aluminum on both sides with a plastic core. It is pretty rigid and cuts easily with regular power tools.

I used the alumapanel for the inside and outside faces of the bunk panel, and it seems to have worked very well. It also has a nice clean white finish.

Thought this might be of interest to others.

[Valleybull]

Sorry, I should have taken pictures, but I did not. One comment I would add though, is that I should probably have looked for a really strong commercial adhesive to stick it all back together for long term success. I no longer have the camper, so cannot provide any update on how it held up.

[Ishmel]

Valleybull wrote:
Kamperdog, Before I did my repair I opened the bunk and it sagged under my weight, so i knew the problem was serious. I ended up taking the whole thing off the camper and rebuilt it from scratch using the AlumaPanel, saving only the aluminum frame and the aluminum channel around the exterior. probably cost $250 for materials and did the labour myself.

Good as new now.

Do you have any pictures of the repair? What was the hardest part?

[Valleybull]

Kamperdog, Before I did my repair I opened the bunk and it sagged under my weight, so i knew the problem was serious. I ended up taking the whole thing off the camper and rebuilt it from scratch using the AlumaPanel, saving only the aluminum frame and the aluminum channel around the exterior. probably cost $250 for materials and did the labour myself.

Good as new now.

[kamperdog]

Whoa. We should talk. I have a 2009 Kodiak 195 and the front bunkend is giving all sorts of issues as well. I believe I have "delamination" occuring near the front bunkend on the curb side of the trailer. The "bubble" starts up near where the "pin" is and goes down to the bottom edge. I will look at that Alumapanel.