Catching up on some Mods and Repairs

[JSBCustoms]

Hello all.
last year I purchased my 2015 19XUD and I have had to do some repairs but also did some mods as well. I thought I'd share with ya.

I had a two roof leaks that needed to be fixed. The first one I found was a Factory goof where Jayco didn't seal the Lag screws that hold the awning bracket near the roof. This caused the OSB on the roof to soften in one spot. I was able to pull the TPO back and replace the bad section and seal everything back up.


The other leak was from a failing front roof cap seal at the corner. I had to replace the Luan curved panel on the inside front where it delaminated. I have found that that the shower fiberglass sheet "Filon" works better than Luan on getting that curve back into place. I also found out how crappy Jayco cares about running wires.

I also replaced the badly sun damaged skylight above the bathroom. Pretty sad to be only 5yrs old.

Mods post to come.

[LuckyDuck]

Nice work!

[norty1]

Nice work when you can make the repair better than new.

[Marcm157]

Awesome work!

[sturgissteele]

Got talent! I haven't ventured into some of these waters, but looks like something I can do. I've worked on cars and motorcycles and all kinds of other stuff, but hesitant working on the roof.

[JSBCustoms]

Thanks!
I'll post the mods to the kitchen and it's interesting story tonight. Ran out of time.

[RichCarter]

How did you first discover the problem please? I'd like to know what to look for.


Was there evidence that the first owner inspected and made appropriate repairs of was the camper previously ignored?


I'm not sure I understand what Jayco did wrong with your awning bracket. The photos show the roof pulled back but I don't see how a side mounted bracket would cause roof damage as shown. I always bed screws with a bit of goop on the threads. A habit from doing boat work. RV builders apparently don't do that.

[JSBCustoms]

Originally Posted by RichCarter

How did you first discover the problem please? I'd like to know what to look for.


Was there evidence that the first owner inspected and made appropriate repairs of was the camper previously ignored?


I'm not sure I understand what Jayco did wrong with your awning bracket. The photos show the roof pulled back but I don't see how a side mounted bracket would cause roof damage as shown. I always bed screws with a bit of goop on the threads. A habit from doing boat work. RV builders apparently don't do that.

I found the leak after we went on a short trip driving the TT in a hard rain.
There was a rust water mark down the wall from one of the valance screws. I didn't have a pic of the bracket but I took a screen grab from a video I took showing my wife the damage. The Upper Bracket has two lag bolts that screw right into the gutter trim which is right on the corner edge where the roof decking and top of the wall meets. the OSB is more absorbent so soaked up most of the water. The 2X wood for the top of the wall had some water damage but that was easily fixed by soaking the wood in thin resin and letting it harden "Stabilize".
didnt get more pics of the whole process. I tend to get busy doing the work and forget to snap some shots.

See attached

[LuckyDuck]

It never ceases to amaze me (and pi$$ me off) how far water can travel and do damage. Kudos to you in tracking it down and repairing so well.

[JSBCustoms]

In the mess of doing repairs I did manage to do some Mods.

Slide out cabinet Headache doors: I added some Pneumatic lift supports to the Doors above the Slide-out. These were a pain when you needed both hands to get out the doggie care bag etc. Guess it would have added another $1K to the price of the camper if jayco would have done this.


Kitchen Counter Top Upgrade + The Cheap Faucet had a crack that would cause water to leak. In turn this caused the back edge of the counter top to swell along the edge and look bad. So the wife said " Lets put butcher block in its place!" Most of you know that Butcher Block is HEEAVY! and its almost 2" thick! She wanted it and as she always says. "I know you'll figure it out!" Dang it! I need to go work for NASA! I managed to cut the slab to size and then cut out the holes for the sink and the stove. I then measured in 2" along the edges and used a big router bit to cut out nearly 1" thick layer of wood from the whole underneath of the counter top. this came in handy when installing the new stainless sink and faucet. I also replace the sink with a light weight stainless sink cause the factory plastic one had micro cracks all in it. Sorry I didn't get pics of the whole process. The slab has 8 coats of poly, wet sanded and machine polished. The back splash we found on amazon and now we are in a debate to run it on up the wall under the cabinets or "My idea" was to top it with trim that I hand carve Campers and campfires finished in Poly. In the end, I managed to only add 13.6 Lbs to the camper with the bigger Counter top.



The last part was I added LED lights under the counter top edge and up front in the area where the dinette table goes that I stowed in the garage cause its useless.



Sorry so long worded and feel free to share your thoughts.

[sturgissteele]

Awesome!!

[LuckyDuck]

Very impressive!

[Marmot]

Absolutely awesome

[Jetboat66]

Dang! Hope you wrapped or put some rubber grommets where the wires are running through the rough cut aluminum. A short waiting to happen.

[JSBCustoms]

Originally Posted by Jetboat66

Dang! Hope you wrapped or put some rubber grommets where the wires are running through the rough cut aluminum. A short waiting to happen.

I cleaned up the rough cut aluminum and then put the wires in a heavy nylon mesh sleeve where it will go through the channel. Yea it's nuts how they did that.