Roof repair and other issues

[cruiserpop]

77 jayco eagle
ok, got the old canvass off, but in the process, didn't like what i found. back1/3 of right side, and entire back side look look rotted pretty bad. Don't know if there's enough wood left to attach the screws to. How would you go about repairing/replacing the wood, or is there another solution,(replacement one peice or other roof) or do i need to pack it in?

had two plates mounted center on the front and rear inside of the roof. Appeared to be a slide-in plate, like the plate on the door you  slide the chain into. is this for a clothesline/accessory,  or is it a lock-in for vital stuff, like the metal uprights for the bunk ends?

[afp]

I posted something some time ago about replacing a roof as you can see below.

I would be very cautious about putting a roof AC unit on. I'm starting to refurbish a 1978 Jayco Jayhawk 6 and I'm in the process of rebuilding the roof. The current roof was in pretty bad shape with serious wood rot in the rear portion. The aluminum skin on the top was in a hail storm and took quite a beating leaving more dimples than I care to count. I would imagine roof construction of your 1977 would be similair to the 1978. The way Jayco constructed the roof is as follows:

1) The perimeter or the vertical pieces (where the awning is located) is made from 15/32" plywood with aluminum covering the exterior.

2) On the inside of the 15/32" plywood is a frame (1.5" high x 1.0" wide) that is fasten to the plywood creating a rectangle. Looks like pine. Down the center of the roof running front to back is another piece of 1.5 x 1.0 strip.

3) The void in between the boards is filled with 1 inch thick styrofoam.

4) The vent has wood framed around it for support.

5) The aluminum skin is bonded to both the exterior and interior.

As you can see with styrofoam being the majority material used in the roof construction I can't see how it would support the unit. Upon rebuilding the roof I thought about adding additional bracing for a unit, but I really don't want to tie additional money into the pop up, plus I'm not sure what the lifting capacity is of the lift system. The only item I will add to the roof is a piece of 1/4" thick OSB to provide additional roof strength. This will be sandwiched between the top of the wood frame/styrofoam and aluminum skin.


Here's an update on my rebuild. Trying to duplicate the construction technique Jayco uses did not work out very well. When I got everything put back to gether the roof sagged a fair amount in the middle. What I can figure is that when Jayco fabricates the roof the wooden frame, styrofoam insulation and aluminum skin is bonded together and put into a press giving the rigidity it needs. I'm in the process of trying a different roof truss that shouldn't have the large deflection problems.

I have pictures of the roof as I dismantled it if you want to see what's under the skin.