Fleetwood Folding Trailers/Coleman ABS Roof

[Tim5055]

I like posting this every once and a while for the new readers who happen by.

Fleetwood Folding Trailers (FFT), which was then selling pop ups under the brand name Coleman introduced the ABS (plastic) roof in the 1996 model year. During the early years of introduction the ABS roof was included on almost all Coleman Pop ps, including some in the Destiny series. So, if you are looking at a 1996/97 Destiny series, check the roof for type.

FFT manufactured the ABS roofs themselves in their Pennsylvania assembly facility. It was soon found that some roofs began to sag for unknown reasons. The first thought was that the A/C unit caused it and they had dealers retrofit the roofs of pop ups equipped with A/C installed units with a metal bar inside the camper to provide additional support. This bar was added as a regular item to ALL pop ups manufactured sometime in 1998 and a retrofit kit was made available for all older units. The absence or presence of a bar in a pop up does not denote a " new" roof.

They continued having problems and other factors were investigated, such as exposure to heat. It appeared that pop ups in warmer climates experienced a greater number of sag cases than cooler climates. FFT tried different formulations of ABS plastic but roofs continued to sag. Additionally, the problem appeared more in 12 foot box pop ups than in 10 foot boxes.

The final cause (as well as anyone can like us can figure out) is that roofs manufactured under certain climatic conditions (temperature and humidity) did not allow the ABS plastic to cure properly. It was these roofs that eventually sagged. The number I hear thrown about is that 10% of the ABS roofs manufactured were bad. I think this number is a little high, but who is to know other than FFT.

Sometine around 1999/2000 Coleman finally stopped making the roofs themselves and began buying ABS roofs from an outside vendor. At his point the the sagging problem seems to have lessened to a degree or disappeared. Now those roofs being supplied by the outside vendor began to exhibit other problems, which have been chronicled on the PUT forums.

They include:

Delamination: Part of the ABS plastic delaminates from the core of the roof and a blister forms on the surface.

Bowing of front & back seal: The seal area of the front and back portion of the roof, where it contacts the box in the down (or travel position) bows up sufficiently to allow water penetration during driving in rain. This condition appears to go away after 24 to 48 hours sitting in the down position. Some believe that the shepherds hook used to push out the bed end canvas pushes up into the seal during use and bends it out of shape. At least 2 differnet styles of seals/gaskets were introduced in an attmpt to correct this problem.

Both of these problems appear to be limited to a small number of roofs.

If you are the original owner of a Coleman pop up defective ABS roof you have little to worry about. The ABS roof has a lifetime warranty.  In 2003 FFT began enforcing the letter of the written warranty and stating that after the first year owners must pay for shipping of the warranty roof to the dealer

Second and subsequent owners do not have the protection of a warranty.  In the past some have reported that FFT seems to be working with these owners to find a solution. The most common solution that has posted here is that FFT will supply a new roof to a FFT dealer if the owner will pay shipping and labor for the installation. They will not ship one to an owner for self installation. Parts prices for the roof itself have been posted at between $1,200 and $2,000 with shipping and labor running between $700 and $900. I have not heard about anyone getting this deal after FFT began enforcing the warrnaty.

Starting the 2003 1/2 model year, Coleman is phasing the ABS roof out and replacing it with the new AlumiTite Krystal Kote Composite Roofs for the GT and GTEs. When the supply of ABS roofs is depelted warranty replacement roofs will only be the new style. I have heard reports form owners that a replacement roof was ABS and others have reported getting a new AlumiTite Krystal Kote Composite Roof in place of an ABS roof. Obviously, there are different roof configurations for different models, so it may take a while until all ABS roofs of all configurations are depleted.

[tlhdoc]

I have wondered about something with my replacement roof. :confused:   My trailer with the original ABS roof came with a life time warranty.  My replacement roof is the new AlumiTite roof that has a 5 year warranty.  I am assuming I still am covered under the lifetime warranty that came with my original roof, but with Fleetwood I wouldn't want to bet any money on it.  The ABS roof was also warranted to cover any type of damage including damage like hale.

[Tim5055]

I have wondered about something with my replacement roof. :confused:   My trailer with the original ABS roof came with a life time warranty.  My replacement roof is the new AlumiTite roof that has a 5 year warranty.  I am assuming I still am covered under the lifetime warranty that came with my original roof, but with Fleetwood I wouldn't want to bet any money on it.  The ABS roof was also warranted to cover any type of damage including damage like hale.

I would think you still have a lifetime "limited" warranty,  Remember, after the first year they can charge shipping for the roof.  But, I asume shipping for you would be around $14.98  

[tlhdoc]

I would think you still have a lifetime "limited" warranty,  Remember, after the first year they can charge shipping for the roof.  But, I asume shipping for you would be around $14.98  

Tim you are close on the shipping cost. :p   My new "free" roof cost $300 for shipping.  The shipping company is sure making out.

[Tim5055]

Tim you are close on the shipping cost. :p   My new "free" roof cost $300 for shipping.  The shipping company is sure making out.

WOW, $300 to take it across the street

[tlhdoc]

I started a new thread about a charge Fleetwood has already made to the new AlumiTite roof.

[Gone-Camping]

Tim... At first I thought why do we need this brought up again? :confused:
 
But this weekend I was up in Richmond checking out Pocahontas State Park for the upcoming spring campout, and ran into a couple of Pop-uppers from Va Beach (yeah, like I gotta drive 2 hours to meet some locals!!!) who had never heard of this website, nor did they suspect there was ever a problem with the ABS roofs. The guy I talked to was a second owner too! He sure listened intently when I explained to him that a lot of these tops have problems!
Guess a good subject matter never goes sour!!!

[Tim5055]

But this weekend I was up in Richmond checking out Pocahontas State Park for the upcoming spring campout, and ran into a couple of Pop-uppers from Va Beach (yeah, like I gotta drive 2 hours to meet some locals!!!) who had never heard of this website, nor did they suspect there was ever a problem with the ABS roofs. The guy I talked to was a second owner too! He sure listened intently when I explained to him that a lot of these tops have problems!
Guess a good subject matter never goes sour!!!

I don't want anyone to say we try to gloss over problems with any manufacturer.

Your story reminds me of one of my own:

I was sitting at Tuckahoe State Park, enjoying the end of the day and a glass of wine when a family pulled into the site next to us.  It was a 12 foot Coleman and looked a little funny when he backed it in.

Once it was up I was shocked!   it looked like a sway backed mule: there had to be 3 inches of drop between  the ends and the center.

I had a hard time starting the conversation, but after I found out he was the original owner I let him know everything I did.

Hopefully by now they have a new roof!