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My camper
May 22, 2013 6:04:12 GMT -6
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Post by 06blackmax on May 22, 2013 6:04:12 GMT -6
Started a new project over the weekend. My pop-up camper has a weak roof so I removed the A/C unit and disconnected everything and took the roof assembly off to see about a repair. (Thank goodness I own a forklift repair shop) Shouldn't be that difficult. So far I've found out its made of an outer fiberglass skin that's glued to a 1"x1" frame filled with foam for insulation and then On the inside a layer of laminated material similar to paneling like used in a house. All the lights are 12v and the wireing is very simple. The sides of the top are made from 5/8" plywood for strength and rigidity. On the underside of the roof there are two metel brackets that run across the roof as support for the A/C unit. Now that's schools out I'm ready for some camping so I'm going to try to have this wrapped up in a week or two. I already have the plywood, now to get some 2x4's ripped down to size for the roof frame and get after it. Thank goodness for power tools, there's hundreds of screws holding the fixtures for the canvas and curtains and all together. Won't be hard, just time consuming. I'll get some picks up later a show some progress.
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Post by Somebody on May 22, 2013 6:06:21 GMT -6
Yes take pics... I've always wondered how hard it would be to fix a pop up since they are mostly glued together..
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My camper
May 22, 2013 21:15:46 GMT -6
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Post by grizzlyadams on May 22, 2013 21:15:46 GMT -6
Cool! Good luck!
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Post by 06blackmax on May 28, 2013 6:34:04 GMT -6
Got some work done over the long weekend. Scraped and cleaned all the rotting and damaged wood out. You can see where it goes here.  The circumference of the top is made from a 1" x 1 1/2" wood frame. In the center of that is styrofoam For insulation and filler. Took some 2x4's and ripped them in the correct size and redid the frame.    Then started in on the sides. They were the worst part but the easiest to fix. One side fell all to pieces taking it apart. This side had been patched in the past. I used it for a template. It's not straight cuts, it's curved top and bottom.   And the new pieces cut and laid out.   Now to finish pulling the laminated ceiling off the let it dry completely. And Install new boards for that. Mike was here last week and we found a couple cracks in the top that prolly started the whole thing. I found some more after cleaning it all up. So to seal it I'm going to use a product that's a cross between truck bed liner and rubberized under coating. Can't think of the name now but it's light and will stay flexible but will make a water proof seal that should last. I'll get more Pics up as I do more. This wasn't as hard as I thought. I'm glad I have a shop full of forklifts to take the top off with other wise you'd have to have three or four guys to hold the top while you unbolt it and then lay it over on its top. The hardest part so far was getting the wood off where it's glued to the fiberglass top. You have to be carefull not to cut thru the fiberglass or you'll create more work for yourself. But this was not as hard as I thought is was going to be. I can see why a camper shop gets $1000-$1500 to do it. It's not hard just time consuming. |
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Post by restoring on May 28, 2013 17:33:50 GMT -6
Michele and I want a pop up camper, but not at the crazy high prices they sell for new.
I've thought about trying to find a used one that needs repair and fixing it up.
This little "how-to" will definitely help anyone facing the same issue. Thanks for posting it.
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Post by mike on May 28, 2013 18:33:42 GMT -6
Looks like it all came apart a lot easier than i thought it would, good luck getting it back together
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My camper
May 28, 2013 18:55:19 GMT -6
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Post by 06blackmax on May 28, 2013 18:55:19 GMT -6
Going back together will be easy now that I know how it came apart.
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My camper
May 28, 2013 18:59:35 GMT -6
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Post by 06blackmax on May 28, 2013 18:59:35 GMT -6
This little "how-to" will definitely help anyone facing the same issue. Thanks for posting it. I found out there are different types of roofs but most of them have the same type of floor. A floor would be easier to fix than a roof. If I can help you make a decision on one let me know. |
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Post by chrisredyj on May 29, 2013 7:24:15 GMT -6
I just sold my pop up. I upgraded to full size tow behind. Only problem I have now is two trailers and one tow pig.  ? |
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My camper
May 29, 2013 11:21:06 GMT -6
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Post by 06blackmax on May 29, 2013 11:21:06 GMT -6
Yeah my wife will pull the pop up with her suburban, and I'll pull the trailer with Jeep or atv's or whatever with the truck.
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?
Just remember...we give them back in 10 months 
It's alive!! 
