Coleman Roof repair

[David Byrne]

We recently purchased a 96 Coleman sun valley
the camper has been sitting outside for most of a month now, I noticed earlier this week that about a foot of the awning track was coming un clued, my local dealer advises would be best to replace the track  today I noticed the entire track and awning has fallen off, I inspected the surface ideally to remove the old glue   on close inspection I have notice several inches of very small cracks in the fiberglass roof just along the roof line and below where the awning track had been attached to the roof actually the track may have covered these cracks  they were not visible as the awning cover obscured then from view  
I think these cracks should be repaired before attaching a new awning track    
This is our first trailer so I am a "newbie" desperate for suggestions on how to best repair this so we can continue to enjoy our camper

[Tim5055]

Well, sorry to be the bearer of bad news......

You don't have a fiberglass roof, you have a roof constructed of ABS plastic.  Plus, due to numerous problems with the roof Fleetwood Folding Trailers (FFT, the manufacturer of your camper) discontinued this roof in 2003.  To read the whole story about your roof, check out The Story of a Roof.

Now, for your repair.  The dealer was giving you good advice whey he said to replace the track.  FFT uses a special glue (probably MEK based) that welds the track and roof into basically one piece.  

Now to  repair the cracks.  The best ABS crack repair you can do is with MEK (MethylEthylKetone) and ABS powder or chips. MEK can be found at most hardware stores as PVC/ABS glue, and it will melt ABS plastic given sufficient time.  While ABS plastic can usually be found at hardware/home improvement store store in the PVC area, it is usually black.  You could also stop by a FFT dealer as they may have damaged roof and wall panels lying out back that they may give you a piece of.

First of all, the repair should be done in a well ventilated area.  The things you are going to be working with PVC/ABS glue and MEK are toxic solvents and are probably not real good for your lungs.  As always, wear clothing to protect your skin and safety glasses/goggles.

1. Drill the end(s) of any cracks to reduce the stress and keep it from cracking further.  It dosn't have to be a big hole, just sufficient size to round out the end of the crack and stop the stress at the "pointy" end of the crack.

2. Rough up the ABS around the crack and clean it with ABS/PVC cleaning solvent.

3. Grind up the ABS plastic you have by whatever method you may have , the smaller the better.  Mix about equal parts MEK and the ABS you ground up in a glass jar (with a lid).  Let this mixture sit for a few minutes , then open the jar and stir the mixture.  Repeat until you have a "slurry" or "goo" of melted ABS plastic.

4. You can now use the slurry of ABS to fill the cracks with.  This slurry should have sufficient MEK in it to melt your slurry to the roof, sealing the cracks.  Work quickly as it dries quickly.  Also, be careful about letting the slurry or ABS/PVC cleaning solvent drip/run down the side of the roof as it can melt/stain the good areas of your roof.

Now, a commercial ABS repair kit is available from The Electrical Connection.  I have never done business with this company, it's not my uncle and I don't get anything out of it.  I'm just passing along information someone gave me.

Good luck