2011 AF990 Nose-cap/Roof Seam Rupture

[BigBlockFord]

Four years of trouble-free service and I have my first BIG failure. Unloaded the trusty 990 from the truck yesterday evening after a wonderfully long weekend of Cascade Lakes camping/kayaking/fishing and noted a couple new 'puckers' at the seam where the cabover nose-cap meets the roof.

After a quick trip up the ladder, imagine my surprise to find the entire nose-cap/roof seam had ruptured! Further investigation showed only a couple of screw holes in the nose-cap/roof seam, which had torn through, suggesting that all other screws missed their marks and the width of the nose-cap seam was only bound via Dicor! I'm actually surprised it held four years!

I'm meticulous on maintenance and actually just looked at the seam in question during our last trip- (had to clean the panels). All looked great. I'll add images hopefully tonight. Just happy this occurred during a dry spell!

Began the dealer/manufacturer repair dance this morning... I've had nothing but good to say about both of them to date. Hoping the stories of Northwood & my local dealer service are proven, since they were one of the keys in my choice.

Will update when I have more. In the mean time, check your major seams

BBF

[kerry4951]

Some will say that the problem should never have happened in the first place. But issues do occur to all the brands as we should all know, and at that point what separates the good companies from the not so good ones is how they exercise their customer service. In this case Northwood took care of a problem on a 4 year old TC that was 3 years out of warranty and that is admirable. Kudos to Northwood!

[Nautique200]

That makes me that much prouder to own my AF1150 knowing they are such a great company and stand behind their product.

[Buzzcut1]

excellent outcome

[jimh406]

deltabravo wrote:
It's nice that a "manufacturing defect" problem that doesn't rear it's ugly head until several years later, is covered under warranty.

I wish all manufacturers would take care of these types of issues, which are probably pretty rare.

Yes, that's a nice job by the manufacturer.

[deltabravo]

It's nice that a "manufacturing defect" problem that doesn't rear it's ugly head until several years later, is covered under warranty.

I wish all manufacturers would take care of these types of issues, which are probably pretty rare.

When I had my Desert Fox, the fual tank sending unit was kaput from the beginning.
I talked to Northwood and they must have provided me with some troubleshooting info, because I remember dropping the tank and taking some ohm readings.
I ended up doing the sending unit replacement myself. Northwood sent me one, under the condition I sent the old one back, which I did.
It was easier for me to do the work than to take the rig to a dealer, then wait several weeks to get it repaired.

[BigBlockFord]

Good news Thursday; got THE dealer call today...

Dealer: Come pick up your truck camper; it's done and we need the space!

Me: Ok, how light is the wallet going to be upon pick-up, since we are a day early than the promise to hear feedback from Northwood on the warranty work? What did they say anyway? (Meanwhile, the email shotgun is getting loaded for bear again to make my case of a manufacturing defect...)

Dealer: Just bring your truck, tie downs, and pigtail. Northwood covered it all.

Me: What? Ok, I'm rollin'!

Had the rig loaded and inspected a hour later, and I have to say, they did a great job. All the old sealant fully pulled, new screws & much wider molding strip, both of which were sealed 'neatly' with Dicor. The dealer went one step further and sealed the front cap edges, again neatly, no slop.

Fellow TC'ers, I have to say, this type of service is what people used to expect as standard practice, but has fallen away as more of an exception today. One of the core reasons I purchased a Northwood product from Guaranty RV in Junction City, OR was the customer service feedback received from happy customers for both companies.

Northwood & Guaranty RV- you have another happy customer that is confident in your products. Thank you!

Now I do need to grab some of that Eternabond... there are a few places it will get used- great info all to helped here. Again, much appreciated!

BBF

[Jeepers92]

Super_Dave wrote:
The front and back seam concerned me within the first year of camper ownership so I broad lapped with eternabond. If nothing else, it has given me some peace of mind for the last 8 years.

On a positive note, that looks like it should be a relatively easy fix.

Mine was ok. Get you a roll of 4" or 6". Eternabond tape. Remove the trim strip and run the tape the entire length of the deam. Place trim piece in correct position where the screws will make good contact. Get new screws 1/4" longer. Predrill the holes and apply calking around screws as you replace them. Replace trim with new caulk, and new lap sealant. I honestly belive you could replace that joint with just the eternabond tape and leave off the trim and it will last the life of the camper and never leak.

[SugarHillCTD]

Super_Dave wrote:
The front and back seam concerned me within the first year of camper ownership so I broad lapped with eternabond. If nothing else, it has given me some peace of mind for the last 8 years.

On a positive note, that looks like it should be a relatively easy fix.

Our new/leftover 2013 EC is going back to the dealer this fall. When we bought it earlier this year, Bill told us that he likes to Eternabond that front seam on the campers he sells.

Seeing the OP's problem really convinces me. YIKES!

[BigBlockFord]

DTR- Yep, no moisture @ all; hat was my first thought -water intrusion-during inspection and figuring how it happened. I grabbed a light and inspected the parameter seams as well as each running light on the nose. All dry as a bone w/o any staining. Lucky I think...

RamTC-along with the initially suspected moisture culprit, I figured delam was also present. (Our prior TC, a Caribou, had mega delam- what mess). In this case, there is no evidence (glue, shredding of fibers, etc...) of bonding ever present between the surface filon and underlayment. The back of the newly exposed filon and top surface of the underlayment are 'baby butt' smooth. This surprised me to say the least. Has anyone else seen this kind of separate surface/underlayment system?

My running theory is wind buffeting & flexing over the past four years finally got the best of the dicor and two screws that found the filon edge. While coming very close, I've never tapped a branch or various other potential overhangs.

Thinking back over last weekend, I do recall a couple of very strong gusts coming west out of the Cascades...maybe the final straw, maybe not.

Local dealer service manager received the set of pictures today and agreed to take it tomorrow @ 1500. will update with results. Thanks everyone for the feedback; I appreciate it!

BBF

[jimh406]

At least it's the dry season for the most part. Thanks for posting the pics.

[RamTC]

Looks like the cardboard type backer material has separated from the Filon so it has "delaminated". That top area should have been flat along the roof line with a sharp bend as it rounds down to the front of the camper. At least you live close enough to Northwood factory, good luck.

[kerry4951]

Looks like the screws were centered in the molding strip where they should be. It appears that the filon front piece was not long enough and the screws missed it. I too ran several runs of 4" wide Eternabond along that top seam right after I got the RV. I did it for extra protection from moisture but maybe it will also now serve another purpose. Thanks for posting.

[downtheroad]

On another positive note, doesn't look like it has been wet or flooded...I'm not seeing any rot or mold.

Good luck with it.

[BigBlockFord]

Thanks Bedlam- much appreciated.
Super Dave- agreed, which makes the backyard mechanic in me start to twitch!

So far the the feedback from both Northwood & local dealer has been brief, but positive. Earliest repair appointment is Sept.1... which knocks out one scheduled trip and bumps into a week long fishing-palooza trip to Central Oregon.

tick tock... will update the TC forum with outcome.

BBF