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Open Roads Forum  >  Truck Campers

 > 98 Corsair 8ft camper roof repair and epdm replacement

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mikakuja

Chilliwack BC

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Posted: 04/17/12 06:59pm Link  |  Print  |  Notify Moderator

My dad recently bought this 98 Corsair camper unaware that it needed roof work so I am doing the repair for him. Thought I would post up my work. Feel free to comment as this is my first EPDM replacement..
At first I was going to repair the rubber roof but as I started to pull things apart I found that the roof was beyond repair... I am sure I could have done it but it would have looked like a patchwork quilt. The PO had driven into somthing and damaged the front right side, tore off the fridge vent and roof rack and damaged the rounded transition strip on the rear. If the repairs had been done correctly the roof would have been fine, but no, the repair was improperly done and as a result the roof leaked in several places.

I am being held up by rain as I do not have a shop to put it in so as I progress I will post up more pics.
I will also be doing a bunch of interior mods and general maintainance work...

Here are some pics of the progress I have made.

OOPS, posted them in reverse order..[emoticon]

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* This post was last edited 04/17/12 11:07pm by mikakuja *   View edit history

Bigfootchevy

Bancroft, Ontario, Canada

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Posted: 04/17/12 08:06pm Link  |  Print  |  Notify Moderator

Looks like you are doing a great job. Keep us posted.

Paul

sabconsulting

High Wycombe, UK

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Posted: 04/18/12 12:00am Link  |  Print  |  Notify Moderator

You did absolutely the right thing to strip it back completely - once the water gets in the damage spreads quickly, and I can see from the pictures it had clearly been getting in in several places. This is what I found when I rebuilt my roof.

Good luck - it looks like you have made a really good start.

Steve.


'07 Ford Ranger XLT Supercab diesel + '91 Shadow Cruiser - Sky Cruiser 1
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mikakuja

Chilliwack BC

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Posted: 04/20/12 09:45am Link  |  Print  |  Notify Moderator

Well, days off are done and basicly nothing done on the camper. Waiting for a couple nice days to finish stripping and rebuilding the roof. On the bright side, I went to the Chilliwack RV show and got some great ideas for upcoming mods on my Desert Fox.... I am now looking at buying a complete solar systm and 2 new 6v batteries so I won't have to run the gen too often. The kids can sure drain batteries quickly........

mikakuja

Chilliwack BC

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Posted: 04/20/12 09:50am Link  |  Print  |  Notify Moderator

sabconsulting wrote:

You did absolutely the right thing to strip it back completely - once the water gets in the damage spreads quickly, and I can see from the pictures it had clearly been getting in in several places. This is what I found when I rebuilt my roof.

Good luck - it looks like you have made a really good start.

Steve.


Nice job on the camper roof.... That's the first one I have seen with a welded one piece heavy aluminum roof.... It will take some serious abuse without failing..

mikakuja

Chilliwack BC

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Posted: 04/28/12 09:58pm Link  |  Print  |  Notify Moderator

Made some progress today before the rain started.... Some of the pics are not very good quality, Iphone doesn't like low lite pics...
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mikakuja

Chilliwack BC

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Posted: 04/28/12 09:59pm Link  |  Print  |  Notify Moderator

I don't know why the pics always post in reverse order.... Oh well...

mikakuja

Chilliwack BC

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Posted: 05/08/12 12:39am Link  |  Print  |  Notify Moderator

The past 2 days have been fairly productive, finished construction on the rear of the camper roof and decided to pull the rest of the trim on the front overhang. Things got a little interesting when I removed the lower trim and water started dripping out. Decided I better remove the fiberglass front cap and inspect the framework for damage. Of course I found more rotten wood, this camper is the gift that keeps giving..... Anyway, I pulled all the rotten wood out and rebuilt the front wall. Now I just have one more small section on the front of the roof to repair and the new EPDM can finally go on.....
Here are some progress pics.

The rear roof complete..
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Fiberglass cap off and the front wall removed
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Rotten wood.
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New framework test fitted and then removed to glue on paneling
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Paneling installed and everything screwed in place.
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Insulated
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Vapor barrier on and ready for the front cap to be installed.
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d3500ram

Colorado

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Posted: 05/08/12 12:59am Link  |  Print  |  Notify Moderator

A labour of love can be very satisfying!

Nice job!

weymard

NORMANDY

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Posted: 05/08/12 02:13am Link  |  Print  |  Notify Moderator

WOW ! Great job !


FORD F250 LARIAT 4X4 DIESEL 2008
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France, Normandy

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