Sagging Roof - Can I brace it?

[Gordo]

Recently bought a 1995 Dutchmen 1002XS.

It has a Coleman Mach AC unit installed, and the roof sags down toward the AC unit. It does not leak, yet, but I am concerned about leaking, and the overall roof structure.

I have noticed pictures of some newer units that have what appear to be cross braces that go across the ceiling on the inside of the camper.

Would that help, and is it something that I could install?
If so, would the roof "pop" out to the original position?
Any other related issues that should concern me or that I should investigate?

Thanks for any help.

[wavery]

Recently bought a 1995 Dutchmen 1002XS.

It has a Coleman Mach AC unit installed, and the roof sags down toward the AC unit. It does not leak, yet, but I am concerned about leaking, and the overall roof structure.

I have noticed pictures of some newer units that have what appear to be cross braces that go across the ceiling on the inside of the camper.

Would that help, and is it something that I could install?
If so, would the roof "pop" out to the original position?
Any other related issues that should concern me or that I should investigate?

Thanks for any help.

The roof certainly should have those braces. Whoever installed the AC on that camper must not have known that.

The roof "May" pop back out to it's original shape if you remove the AC unit, install the braces, then re-install the AC unit. You won't know until you try.

One thing is for sure, if you leave it the way that it is, you will definitely have structural and leaking issues (if you don't already). That roof derives it's structural integrity by being slightly arched up. When you remove that upward arch, the roof loses all of it's strength and will ultimately (and possibly suddenly) fall apart.

[4Campers]

Recently bought a 1995 Dutchmen 1002XS.

It has a Coleman Mach AC unit installed, and the roof sags down toward the AC unit. It does not leak, yet, but I am concerned about leaking, and the overall roof structure.

I have noticed pictures of some newer units that have what appear to be cross braces that go across the ceiling on the inside of the camper.

Would that help, and is it something that I could install?
If so, would the roof "pop" out to the original position?
Any other related issues that should concern me or that I should investigate?

Thanks for any help.

We have a 1994 Dutchmen 1002XS. Purchased it new in '94. The A/C was added as an option from the dealership. They added two U shaped bars to the ceiling inside, bolted all the way through the side of the roof. We have had no sagging problems, but did have roof leaks above the door. Our A/C unit is a Dou-Therm, which is probably larger and heavier than your Coleman.
I would worry about sagging and roof damage. There are no replacements for them anymore. I have to agree with the first reply. Remove the A/C unit, brace the roof, and re-install.
I could shoot some pics next trip if you want ideas. I have pics of the pup, but nothing of the ceiling. Maybe a 1" to 2" U-channel steel piece, measured to inside. You would have to have a plate welded in the end for a bolt attachment. Scary part would be drilling the holes through the side for the bolt. Lots of caulk to cover bolt heads.

[austinado16]

The roof certainly should have those braces. Whoever installed the AC on that camper must not have known that.

The roof "May" pop back out to it's original shape if you remove the AC unit, install the braces, then re-install the AC unit. You won't know until you try.

One thing is for sure, if you leave it the way that it is, you will definitely have structural and leaking issues (if you don't already). That roof derives it's structural integrity by being slightly arched up. When you remove that upward arch, the roof loses all of it's strength and will ultimately (and possibly suddenly) fall apart.

^^Agreed^^

If you can't buy the braces, you should still be able to repair this yourself and have a nice outcome.

I'd suggest (as did Wavery) taking off the A/C unit and see what the roof does.

If it doesn't flex back into shape, you can force it into shape by standing something upright inside, and then cranking the roof down until the roof is being pushed up by the support you've put inside.  Something like a 5-6' folding ladder with a thick towel folded up on top of it would work great.

Plan things accordingly, and you'll be able to get the roof pushed up to the right curvature, and then have a couple of braces made that are curved on top to match the correct roof position.  Then mount them to the side walls and center spar of the roof (if it's built that way).  That'll force the roof into that position permanently.

You could do your braces out of aluminum using the talents of your local welding/fabrication/machine shop type places.  An "I" beam shape in cross section would be simple and easily drilled and mounted with a couple flanges at each end......sort of like installing a roof truss for a flat roof.

[mike4947]

Just as an FYI the mid 1990's Dutchman roofs are prone to failure. Many reports of leaking roofs not showing any damage until they weighed enough to crash the lift system. Make sure the core is dry.

[Gordo]

Thanks for the replies everyone.

After doing a bit more research, as Mike mentioned, it appears that Dutchmens had some serious roof issues (with or without AC) especially on 95 & 96 models, and often had to have the roof replaced.

I don't mind putting a little work into it though. We got it at a really good price, since the lift cable was broke. That only took a couple hours to repair, and everything else appears to be in good shape.

Our last planned trip of the year will be over labor day weekend. After that, I will get it into the shop and start with taking off the AC unit as suggested, and see if I can get the roof back to the original shape.

Since the roof is sagging, the top covering is also bubbling up in a few areas. While I have the AC off, what else should I be looking for?

As to the roof supports, so far I have called:
-Dutchmen Parts Dept. (no help, didn't seem to know what I was referring to)
-Local Dutchmen dealer (he was going to call Dutchmen as well)
-Local Coleman dealer (knew what I was talking about, but recommended that I try to find the original Dutchmen part, wasn't sure if the Coleman braces that he could get would be sized right)

I suppose I could get something custom made, but finding the original parts that are sized correctly would simplify the process.

4Campers - if you could snap a couple of pics of yours, that would be great.

[Gordo]

Good News :#

Parts guy from the local Dutchmen dealer said that he can still get the roof supports from Dutchmen. $50 each.

I should probably get 2 of these shouldn't I? Install one them about 1/3rd from the back, and the other about 1/3rd from the front.

4campers - If you get a chance to take any pics, closeups of how they are attached on the sides would be awesome.

Thanks again everyone.

[wavery]

Good News :#

Parts guy from the local Dutchmen dealer said that he can still get the roof supports from Dutchmen. $50 each.

I should probably get 2 of these shouldn't I? Install one them about 1/3rd from the back, and the other about 1/3rd from the front.

4campers - If you get a chance to take any pics, closeups of how they are attached on the sides would be awesome.

Thanks again everyone.

That is good news..... :U

However, I'd take the AC off and inspect that roof for water intrusion first. If the insulation is wet, you'll have to take the ceiling out of the PU and remove all of the insulation and replace it.

Check for any wood-rot. Remember, wood-rot is a living organism. It must be totally eradicated or it will continue to spread. Don't waste your $ on chemicals that claim to "kill" wood-rot. They can only kill the surface bacteria. Heck, you can do that with bleach. Chances are, the bacteria is embedded far into the wood and nothing that you put on the wood will penetrate more than about 1/8". The wood must be cut out and replaced to do a proper job. In the end, you'll find that to be easier anyway.

If your roof material is plastic, you may try putting heat lamps over it to warm it up. When the plastic gets warm, it will normally "Remember" it's original shape. Most plastics do have a "memory".

One of my neighbors came home the other day with a big old dent in the plastic bumper on her brand new Mercedes. I told her to go to her insurance company, make a settlement then come see me. She came back with a check for $4500. I put a heat lamp on the bumper and in the morning you couldn't tell that it was ever touched.........(as a side note.....I never saw a penny of that $4500  :swear: ).

Good luck and I hope that everything is tight and dry in there.

[4Campers]

Good News :#

Parts guy from the local Dutchmen dealer said that he can still get the roof supports from Dutchmen. $50 each.

I should probably get 2 of these shouldn't I? Install one them about 1/3rd from the back, and the other about 1/3rd from the front.

4campers - If you get a chance to take any pics, closeups of how they are attached on the sides would be awesome.

Thanks again everyone.

That's great that the original braces are still available. $50 is less than having something fabricated. I would buy 2, and place them about 12 inches in front and behind the roof opening for the A/C. I don't think ours are centered, but off center a bit on the inside ceiling.
When you pull yours apart, look for any wood rot. The interior wood of the Dutchmen roof is just cheap pressboard, snadwiched between the outside skin and a thin white interior film. Where we had a leak above the door the wood was just like powder. Had to scrape all the old wood off down to the skin. Replaced it with 1/2" plywood and construction glue, painted it, and so far seems to be holding well. We used Eterna-Bond on the roof edges to seal the roof leak. Looks kinda crappy, but it works. Our next trip out is not until Sept 5. I'll shoot some close ups of how our roof supports look and attach.
The pic here is a good shot of the side. The two sets of bolts (if you can see them in this compressed pic) on the roof are the support anchors.

[mike4947]

Make sure you and the parts man are on the same page. There are roof supports and roof supports. One goes across the trailer and mounts to the roof itself and the other is just uprights placed at the corners to hold the roof up in case something breaks.

[wavery]

Make sure you and the parts man are on the same page. There are roof supports and roof supports. One goes across the trailer and mounts to the roof itself and the other is just uprights placed at the corners to hold the roof up in case something breaks.

Good catch Mike........that's a very likely possibility that there could be a misunderstanding there.

[Gordo]

Good catch Mike........that's a very likely possibility that there could be a misunderstanding there.

Thanks, I'll double check, but I think we are on the same page.

I described the situation to him (sagging roof, spanning the inside...) so I hope they are what I am looking for.

[austinado16]

Glad you found the actual parts!  I hope you find the roof is good inside.  The entire front of mine was rotted out completely, so I've been down your road!  Good times for sure........ :mad:   But I only paid two-fitty for the camper, so I had some money left over to by a sheet of plywood, some glue and a bag of screws...  

[4Campers]

Make sure you and the parts man are on the same page. There are roof supports and roof supports. One goes across the trailer and mounts to the roof itself and the other is just uprights placed at the corners to hold the roof up in case something breaks.

This is a good thought. On the Dutchmen's there are two U-shaped supports they use on the corner lift posts for support while the roof is up.

[4Campers]

Gordo-
Have you found the supports yet? I was out this past weekend and took some pics of the inside and how the braces attach. I have several, to big to post here. If you want to send me a private e-mail I can send them to you. You can use my main email which is tbanishsr{at}cinci.rr.com