Roof AC shroud replacement

[fshnfool76]

Can anyone tell me where I might find a used replacement top part of shroud. It's on an '89 Coleman Chesapeake that we bought last year. The model # on the ac is unreadable. It is a Coleman ac unit tho. Something must of hit it over the winter and put a hole the size of a baseball in it. Thinking of just using duct tape since a new one is $150.00. Thanks :!

[tknick]

Found a couple of links...ppl motorhomes tuffmax (generic that will fit) 119.75.  campingworld 129.99 for a coleman replacement.  I think you would just have to get lucky to find a used one.  I'd check with you local dealer and see what they do with old tired campers.  I'd also check with some local salvage yards.  they may have an old camper or two lying around.  it doesn't have to be a popup, just have a coleman a/c on it.

good luck
travis

[fshnfool76]

Thanks for the suggestions Travis! I'll call the salvage yards and dealers tomorrow.   Alan

[wavery]

If the shroud is plastic (not polyethylene), it should be easy to patch it with fiberglass.

You can buy small fiberglass repair kits at most big hardware stores or marine stores. I would put a piece of saran wrap around a small piece of wood then duct tape that piece of wood over the hole to form a backing for the F/G patch.

Turn the shroud upside down and make your fiberglass patch on the inside (following the instructions on the pkg). After the fiberglass cures, remove the duct tape and saran wrapped backing (the saran wrap is to keep the F/G from adhering to the backing material. F/G will not adhere to saran wrap).

When you remove the tape, the recessed part of the hole will still be there. For a more custom finish, you could fill in the recessed area with a thin coat of bondo, sand it, put another thin coat of bondo to level it out, sand it again and paint the entire shroud. You will never know that there was a hole.

If you're not concerned about the custom finish, just put the F/G patch on the outside of the shroud and put your backing on the inside. After the F/G cures, remove the backing and paint your shroud. Just remember that the patch will still be visible after you paint.

[fshnfool76]

If the shroud is plastic (not polyethylene), it should be easy to patch it with fiberglass.

You can buy small fiberglass repair kits at most big hardware stores or marine stores. I would put a piece of saran wrap around a small piece of wood then duct tape that piece of wood over the hole to form a backing for the F/G patch.

Turn the shroud upside down and make your fiberglass patch on the inside (following the instructions on the pkg). After the fiberglass cures, remove the duct tape and saran wrapped backing (the saran wrap is to keep the F/G from adhering to the backing material. F/G will not adhere to saran wrap).

When you remove the tape, the recessed part of the hole will still be there. For a more custom finish, you could fill in the recessed area with a thin coat of bondo, sand it, put another thin coat of bondo to level it out, sand it again and paint the entire shroud. You will never know that there was a hole.

If you're not concerned about the custom finish, just put the F/G patch on the outside of the shroud and put your backing on the inside. After the F/G cures, remove the backing and paint your shroud. Just remember that the patch will still be visible after you paint.

      This is a good idea too. I've never done F/G repair before but seen it done. I'll give it a try if I don't find a cheap replacement. Haven't made those call yet tho, hopefully tomorrow.  Thanks---Alan

[wavery]

F/G is easy. You will get a small container of polyester resin and a 50-1 catalyst. You will also get a piece of F/G cloth. That is just what it is.... a piece of cloth, nothing mysterious about it. You will also need a 1 1/2" cheapo brush.

If you have a 5" diameter hole, cut 3- 7" diameter circles out of your cloth. Each circle should be a little bigger than the first. (Tip..Never have a square corner in F/G)

Mix about 1 cup of resin with the 50-1 catalyst and let it set for the time listed (usually about 10 minutes).

Clean the area around the hole in the shroud with acetone.

Put your F/G cloth circles on a piece of fiberboard, glass or any flat, disposable surface (even cardboard).

Dab on enough resin to the smallest piece of cloth to just get it soaked, don't over due it. You will be able to tell if there are any dry spots.

Brush a thin later of the mixed resin on the surface that the cloth will be placed on (including the saran covered backing).

Carefully pick up that wet piece of cloth and lay it evenly over the hole. You will be able to move it around after you put it down. Now, take the end of your brush and dab out any air bubbles.

Do the exact same thing with the next biggest piece, then the last piece. You just put them on top of each other, wet-on-wet. Each piece over-lapping the piece before.

Let it set for about an hour, then trim of any rough spots with a razor blade. You will be able to sand it to a smooth finish in about 8 hours. Let it sit, sand (120 grit paper) and paint it the next day. Don't even think about not sanding. During the curing process, wax comes to the surface. It must be sanded off.

Make sure to wear protective gloves. You can use acetone for clean up.

[fshnfool76]

Well, I still didn't fix the shroud yet, which is okay since the PU hasn't left the driveway yet do to lack of time, BUT. I did go to a couple of dealers around here looking for used as was suggested. Instead of finding a cover, one of the dealers was having a tent sale getting rid of used and overstock stuff and I found a complete (used but looks like new)4 bike Thule roof rack system for $100! It will be attached to the pup this weekend. I was planning on building one of the pvc ones that other guys have made and now don't have to. As for the shroud, duct tape for now. It will be getting the fiberglass treatment that wavery suggested tho. Thanks to all.  alan