How to fix a cracked fiberglass roof on a popup

[nbrewer]

I am thinking about purchasing a 2001 Coleman Sunvalley from a coworker for a really good price. But, they originally had this popup in Arkasas, where it sat and baked in the sun most of the time. They hauled it from AR to KY about two years ago, put a tarp over it, and really haven't used it much since then. But, the sun in AR did a number to the roof. The current owner said there is a crack in the fiberglass roof, and he feels the entire roof would need to be replaced.
So, should I think about an entire replacement? Or is this something that can be repaired? It's fiberglass, I would think I should be able to repair it, but I haven't seen it yet. Cost wise, does it even make sense to consider repairing it? I'll be going to see it for the first time this coming weekend, and want to make sure I know what I'm looking for.

TIA,
nbrewer

[Ron3rd]

Hornnumb2 wrote:
Run away unless you are going to replace the roof with a new one. They are ABS and nothing sticks to them but abs. I tried patching my cracks with a abs flakes and mek solution and they came back, next step was rhino liner which last about one year before it started cracking. More than likely the roof also has some bowing where there is a gap in the from and back allowing water in while traveling. I really enjoyed my Coleman except for the roof, I ended up buying a late model used roof from a salvaged trailer and had it shipped from CA to TX.

Good advice, a buddy had a same era Coleman PUP and had the same problem, which he later found out was common on their PUPs of that era. He patched with several products over the years and it looked like @#!%. He finally got rid of it. He also considered the new top at $500 but said the shipping by truck was something like $400-$500 alone. His top was plastic BTW.

[nbrewer]

With everything I've read, I don't believe I have the skillset to complete the job. So, I'm going to decline the purchase.

Thanks to everyone for your advice and opinions. I'll just wait for something better to come along.

Thanks!

[Hornnumb2]

nbrewer wrote:
Hornnumb2, would you be willing to share the cost of buying a new (used) top and having it shipped? I can't imagine that's cheap.

I gave $300 for the top but it cost $900 to ship it here. I started putting it on but the track was higher up in the new top and would have to be moved down to make it work. I ended up sticking the old top back on and sold the package for $2300 and let somebody else mess with it. There is plenty of threads about the Roofs and fixes that have been tried over at popupexplorer forum. The only way water can get in is through the bowing of the roof. The foam between the 2 layers of ABS is closed cell so it does not soak up water. I did check on a new roof and if i remember correctly it was about $3000 plus shipping but they have closed since than. Good luck if you decide to jump into it.

[zedd]

We had a late 90's Coleman with the ABS roof. It was a nice trailer until the roof started to disintegrate. Once the cracks start you'll never be able to keep up with them. IIRC, the cost of a replacement roof was a few thousand dollars. I doubt they're still available. We were the second owners so the warranty didn't apply. We ended up giving it away. I don't know what happened to it. Too bad...they were nice trailers except for the roofs. I don't think I'd take one even if it was free. OTOH, if you're good at woodworking you might be able to build a roof out of plywood covered with fiberglas.

[RJsfishin]

A good RV shop will weld ABS plastic,....they weld up cracks in ABS holding tanks quite often, except mine, said they could would do it, but guarrany to the door. It fell out on the hiway from a tire blow out, got run over by a Mack truck :))

[riven1950]

This stuff worked great for me on a plastic kayak, but if the top is brittle or crack too big it may not be worth the effort.

http://www.westsystem.com/ss/repair-kits

the 655k is for plastic repairs.

[nbrewer]

Hornnumb2, would you be willing to share the cost of buying a new (used) top and having it shipped? I can't imagine that's cheap.

[John_Wayne]

Also look very carefully for water damage if it's cracked water has entered and that will be a bigger problem then the crack.

[DaHose]

Eternabond is a pricey, but good alternative.

ABS can be easily repaired with a welding kit. You can get one that looks like a soldering iron or one that looks more like a heat gun. I prefer the soldering iron type, but it takes longer. If it is not completely brittle and just needs cracks repaired, then I would consider buying. If it is COMPLETELY sun rotted and brittle, I would leave it be or be very ready for a massive repair project.

Jose

[Hornnumb2]

Run away unless you are going to replace the roof with a new one. They are ABS and nothing sticks to them but abs. I tried patching my cracks with a abs flakes and mek solution and they came back, next step was rhino liner which last about one year before it started cracking. More than likely the roof also has some bowing where there is a gap in the from and back allowing water in while traveling. I really enjoyed my Coleman except for the roof, I ended up buying a late model used roof from a salvaged trailer and had it shipped from CA to TX.

[BarneyS]

Moved to Tech Issues forum from DIY.

[nbrewer]

Thanks for the tips everyone. I'll be going this weekend to take a closer look, and will return with some pictures. From the research I've done so far, it doesn't look like it's terribly difficult to do the repairs. More time consuming than anything. But with winter just around the corner, that'll be just fine!

[mbutts]

$500 doesn't sound bad since Coleman/Fleetwood used to charge double that for the shipping of the warranty roofs.

It might not have been the AR sun. My '99 Coleman had very stern warnings to NEVER cover it with a tarp or roof damage would occur.

[RoyB]

You may want to try out the ETERNABOND strips to see how that adheres to the plastic roof.

You can get 3" x 24" short repair strips from WALMART and maybe try it out on an out of the way place on the roof to see if it works right.

You hear nothing but good results from the guys on here about ETERNABOND fixes for the roof...


You must follow the install instructions to the tee especial the pre-work getting the roof ready before you apply the eternabond tape



If it works ok for your roof then go online and purchase longer spools of the Eternabond tape...


Roy Ken