Toy Hauler Nose and Roof Replacement

Joe417 wrote:
I've done a couple of jobs like you are describing. I experimented and the only adhesive that worked well for me was polyurethane, such as Gorilla glue. It is moisture cured and doesn't need air to dry. It's also fast compared to any of the other types that I tried.

Polyurethane expands while curing if not contained.
The only issues that I had was figuring out how to press the filon on to the substrate so that the polyurethane didn't push it away from the surface while curing.

The first job I did taught me a lot because I ended up doing it twice. Thankfully my wife helped me clean up the mess that didn't work, Scraping, very carefully, the polyurethane off. An 8x8 piece of filon seems huge when your doing that.


yeah thats what i was planning, lay the backing panels. 1/8 plywood basically, on the frame and use liquid nails or GG to bond it and clamp till cured.. then seal up the seams with polyurethane, cure, then use contact cement working my way up from the bottom pushing out air bubbles and finally securing it by laying backing boards on top of the filon and then 2x4's across the backing board secured with ratchet straps till cured..

You'll most likely need to put what ever you're using as the substrate on first and then attach the filon. Filon and 1/8" plywood bonded together doesn't bend very much at all. Yes, I tried it. But the front cap I was rebuilding had much sharper curves than yours.

Others on the forum have done a lot also. If you'll post some picture other will probably chime in as they have done similar repairs. Also, if you have specific question, ask, somebody has done that before.