Rotted roof repair on Starcraft

[austinado16]

Avert your eyes if you don't want to see this!

The previous owner had spanned the inside front of the roof with two 1x4 redwood planks bolted through the entire roof "skin."  I knew this was going to be ugly.......and man was I right.

The entire front verticle section of the roof........which is a piece of OSB (oriented strand board) plywood glued on one side to white painted aluminum sheet for your inside white ceiling, and the dimpled aluminum sheet used on the roof glued to the outside........was soggy, damp, and completely decomposed.

The 1x2 wood cross member at the leading edge of the horizontal part of the roof was equally decomposed for about 90% of it's length.

The 1x wood the runs right down the middle of the roof under the seem of the sheet aluminum is rotted about halfway to the centered roof vent.

The verticle sides are also rotted to about 18" back on the left side and maybe a foot back on the right.

I knew it was like this when I bought it 6 weeks ago, and only paid $250.00....so I definately got what I paid for.

The plan is to section in some CDX or Marine Grade plywood, saving and regluing the white aluminum skin on the inside and the textured exterior skin.  I'll replace the middle 1x and the leading edge 1x and maybe ad an "L" shaped aluminum or steel channel to reinforce and have something to screw into for better structural support.  Once it's back together, I'll go to the upholstery shop and have them work a little magic with the ceiling.

Any BTDT's welcome!!!!

[qwazert]

OMG...good luck on this one!  :yikes:

[austinado16]

Got the sides finished and installed a new front cross member that I cut out of a pressure treated 2x4.  On to the front verticle piece next.  Then come up with a plan to replace the rotted out/destroyed piece of 1x that runs down the middle of the roof.

Fun stuff....for sure.

[austinado16]

Starting to go back together now.  So far, so good.  The sides where I've butt jointed in new 1/2 OSB are super strong and rigid.  I installed the new front panel with the roof supported just slightly bowed up and now with the panel in place and acting like a truss, the roof is strong and back into its correct shape.

I was able to splice in a new stringer running from the center of the front down toward the roof vent.  I cut the rotted one back until I found good wood, then using chisels, shaped the end of it into a step.  The new piece had a matching step and once glued and screwed seems fine.

I'm mounting front skin and the corner moldings now.  Then I can put on the lower trim and gasket.  

When that's all done I can deal with the damaged skin down the center roof seam, and the trim that covers it.

[wavery]

Looks like a fun project.  Keep us posted.

[Hunt4Fun]

I feel your pain.


http://new.photos.yahoo.com/jack.kissner@sbcglobal.net/album/576460762381271476

[austinado16]

Hunt4Fun your photos are fantastic, and your work incredible!  I'd stumbled across your album a few weeks ago when searching the forums and finding any related info on tearing apart one of these roofs.

As for today's progress, the exterior is all back together, except for the tan vinyl strip that pops into the seam and corner moldings on the outside.

Where the top seam was eaten away under the seam cover molding, I found a product at the local RV place that comes on a roll.  About 6" wide 1/16" thick and as long as you want.  Sticky on one side, white rubber on the other.  So, this is down centered on the roof seam, and then I screwed the molding back down with 1/2 #8 stainless philips head screws.  

I'm not happy with this visually, because it's a white strip on my tan roof and looks pretty "rookie."  But, I think if I can paint to match, it'll be fine, and it's definately waterproof.

The roof is super strong again too.  I actually put the left over sheet of 1/2" OSB on one half of the roof and then kneeled up there to install the patch, molding and screws.

The next adventure is going to be redoing the white ceiling vinyl.  I also need to drill holes and remount all the fasteners that hold the roof to the telescoping legs, and the metal clips for the closing latches, and install the rails for the canvas.

Here's a shot of the progress so far....

[Hunt4Fun]

That looks great!  Nice work!

You may decide to add metal plates on either side of the roof where the lift system connects.  I did not do that, but I'll be watching for wear in that area.  I used 3/4 inch solid lumber for the roof and like all the exterior, it is painted with 2 coats of Kilz primer and then 2 coats of semi-gloss enamel.

I have not decided what to do about the exterior.  It's weather proof the way that it sits now, but it looks like a box.  I'm not sure what to consider for panels.  I had looked at some corrugated panels but the color was a hideous green.  I was hoping to find something in hunter green.

I've spent the entire day working on it today.  The running lights are on and just need to be connected up.  The 110 outlets are in (4 of them) and the electrical box has a new circuit breaker.  I'll take some more pictures on Sunday.

Right now I'm ready to crash and watch the Hoosiers play UCLA.  I don't have a good feeling about the game for the Hoosiers sake, but if they start raining 3 pointers in, it could be interesting.

Take care and best of luck on your project.

Hunt4Fun

[austinado16]

Thanks and pardon the filthy look.  I still haven't polished and waxed the exterior....figuring there's no point when I'm in mass destruction mode.

Have you thought about having your roof "Rhino Lined?"  I don't know if they can spray that stuff onto painted wood or not.  I'm seriously thinking about having my roof done in it.  Or at a minimum, I may blast that patch "stripe" with some paintable undercoating to give it some texture sort of like the roof has, and then try to paint to match the roof.

I haven't put in any of the front fasteners yet, but I intend to make sure they're bedded in some caulking and very tight to get a good strong crush on the wood and aluminum.

And it won't be left sitting outside without a cover!

[Hunt4Fun]

I have thought about it, but I'm not sure how much weight it would add.   I have Rhino on my current truck and had it on a previous one.  Great stuff, but I'm hoping to take the pop up over and have it weighed in the near future.

Yesterday was very productive.  The dinette is functional and I expect to finish up the wiring Sunday.

Then it is ready functionally for turkey season at the end of April.

[howlinowl]

Whoo boy.  Nice work on both those.  I seriously doubt I'd have the ambition to tackle either of those.  

Allan

[ScouterMom]

That roof was really something - what a mess!

But Hunt4fun, your 'project' is unbelievable! is there anything left of that 1976 camper except the frame?  are you going to use the old 'skin' or a completely new cover? That is a really impressive job!


I just bought a 73 starcraft - looks to have been close to the size and configuration of your '76 - I haven't got it home yet.  Before I can get a really good look at it, I have to get the lift cables replaced so I can GET the lid up and look at it!  But I might be calling on you for your obvious expertise.... is that OK?

I have a question maybe you know the answer to - I noticed in your starcraft there is a long tube maybe 4-5" in diameter, running the width of the back of the camper (it's in your pic # 008) - My 73 has this, also.  What is it for? poles?  it only opens on one side, and mine appears to have a missing or broken cap, and nothing in it but dust and spiders.


Laura

[ScouterMom]

Hunt4fun,

Theres a re-done camper on e-bay - looks very different - the guy covered the whole thing with diamond plate steel - here's a link -

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&ih=018&sspagename=STRK%3AMEWA%3AIT&viewitem=&item=280094599950&rd=1&rd=1

(if the link doesn't work, it's item no 280094599950)  it looks really nice, and will probably wear well and reflect heat, too! I don't know how expensive it would be, or how heavy!

Laura

[Hunt4Fun]

ScouterMom,

I've kept a few things outside of the frame:  The 110 box and outside electrical cord, the winch and lift system is pretty much original.  I disassembled, cleaned, painted and lubricated it, but the parts are the same.  The sink and stove are original, but the plumbing and copper tubing to the stove is new.  Oh, and I kept the door, but it has not been installed at the top as yet.

I'm always glad to help in any way.  Message board or email is fine.

The long tube in my starcraft was for poles.  I haven't sorted all of them out, but the 4 poles to support the beds were there and some other that looked to be for an awning from the past.

The old skin is in the trash, and I have not decided what to put on the outside as yet.  I'm still looking at options.  

The unit on ebay looks nice, but I would concerned about the weight that the steel adds.  I tried to stay with wood, but I did increase from 1X1 framing to 2X2.  I was really surprised that it was manufactured with 1X1s.

Best of luck with your repairs.

Hunt4Fun

[howlinowl]

Well, Hunts4Fun.  Since you are replacing the canvas, why not get some camoflage for the tent.....and paint the trailer to match.  Would be cool, except it might be hard to find the trailer when you get back from hunting.

Allan