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Old 05-03-2013, 01:06 PM   #1
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Roof Leak/Ceiling buckling--how to repair 2005 19H

This I am certain is related to the thread on A/C gaskets leaking, but the damage is done.

The ceiling of my trailer has started to "wrinkle" in various locations, and a couple seams have opened a bit. I am told by a local dealer that water has wicked from the A/C unit throughout the roof and the entire thing will need to be replaced. Ceiling feels soft if I push up on the wrinkled areas.

Roof looks ok, but a few depressions or low spots.

I pulled the lights/speakers to have a look and can see that the roof layer of the plywood/luane is damp.

Questions on how to best fix this. I understand the roof is a layer of styrofoam sandwiched/glued between these plywood/luane layers. I think therefore I can't just pull the luane down inside (it's also under walls/cupboards) and replace. It also looks like it has metal trusses inside the ceiling. RV service place says I have to replace the entire roof panel as 1 thing and the cost is scary!

Roof itself I have read enough to say I can pull off the existing membrane and see where exactly it's leaking and what areas of the luane need repair, re cover the entire roof with new luan if necessary and the put the old (if it's salvageable) or a new membrane down. Does this make sense to do?

If I don't pull off the existing membrane and just replace the A/C gasket will the wood ever dry out? I could live with the slighly wrinkled ceiling i guess.

Thoughts, comments or experienced words greatly appreciated. The rest of this trailer is immaculate.
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Old 05-03-2013, 04:04 PM   #2
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Bummer but I feel ya. I have some "pumpkin-ing" or bumps forming on a few spots on my celing around the area from my AC leakage. Also noticed 2 small areas of where the white interior celing material starting to wrinkle and can push up on. the roof (exterior) is solid but just looks like the leak caused seperation on the interior portion. Ours isnt nearly bad enough to warrant a tear down and replace "yet" but I understand what your going through. I've ran through a few ideas how to fix it myself but havent seen the need just yet. It wont dry out unless you remove the water damaged panel and replace it after its dried. If your not too picky and want to save some $ I think you could get a replacement panel piece from your dealer $$ or get a nice thin wood sheet from Lowes or HD and paint, then cut and attatch and seam tape the cut edges to blend with the good un damaged celing. Now, if its gotten in above cabinets etc all thats got to be removed but at thats the case might as well replace from wall to wall. Long story short......CHECK YOUR AC GASKETS EVERYONE!!
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Old 05-06-2013, 09:13 PM   #3
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Starting peeling back the ceiling and not too happy. Does anyone know if you can order the full roof panel from jayco? Im think 5-6 guys could lift it into place
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Old 05-06-2013, 09:50 PM   #4
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Just thinking out loud.

I guess I would peel off the inside ceiling cover and the outside membrane.
I would allow everything to dry out and see what needed replaced.
I would replace outside sheeting with luan spanning trusses where necessary.
I would replace the inside luan sheeting in the same manner.

Any smaller areas of damage, I might repair with epoxy and sand smooth. They make an epoxy wood restorer.

I would then replace the roof with a new membrane or rubber roofing material.
You might even be able to apply a liquid rubber roofing over luan with proper primer. Check with rubber roof manufacturer.

I would apply a vinyl butt joint wall paper on the ceiling and trim out. You can even buy textured wall paper from Home Depot or Lowes.

Best of luck,
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Old 05-07-2013, 07:03 AM   #5
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Man either way it sounds like a lot of work, more than my "skill" level would let me do.

Better to take it to a dealer and have them do it.....
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Old 05-07-2013, 08:22 AM   #6
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More thinking out loud.

Maybe open some holes in the interior ceiling panels and use some cold air return grills to cover/trim them out? That would encourage air circulation for drying. The grill covers come in some fairly large sizes. Maybe big enough to hide some of the ceiling water marks? A dark color screen material glued or otherwise fastened on the inside of grill vents gives a more closed off appearance, but still allows air to move.

Boats use little fan powered ventilators (12 vdc). One mounted in the inside ceiling panel would help air circulation in the chamber a bunch if coupled with grill vent openings. The pancake fans used in computers are also 12 vdc. They can be salvaged and installed above the ceiling to help to move the air.

I'm working with some water problems on our older trailer. So far it seems we may be winning the battle, but time will tell. Good luck.

vic
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Old 05-07-2013, 10:02 AM   #7
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Thanks for the thoughts folks.
Further info... as I tear this apart a bit to further investigate... the ceiling is plywood, styrofoam plywood all completely glued together with Aluminum joists... there is no air cavity in the ceiling for air to pass through, and no wood joists to screw any new Luane/plywood into. Perhaps I could use self tapping screws and go into the Aluminum? Peeling the plywood off the ceiling is going to be a challenge it is so well glued... using a long handled scraper to try and get in there to minimize the damage to the styrofoam. I haven't taken off the membrane yet to see how far the damage is up top.

As for taking to the dealer... I think it will be 4-5K on a trailer worth maybe 9K... and I was looking to sell it and upgrade this year....

I really think if I could get a new roof panel it's the easiest fix (definitely not the cheapest!)... it appears to be just screwed down from above into the walls and it's one big piece.. guessing it can't weight more than a couple hundred pounds. I already have all the cabinets out. It's certainly the best way to do it.

I left a message at the Jayco parts line and sent an email off to Jayco to see what they suggest.
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Old 05-07-2013, 08:03 PM   #8
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Quote:
Originally Posted by Yellzee View Post
Thanks for the thoughts folks.
Further info... as I tear this apart a bit to further investigate... the ceiling is plywood, styrofoam plywood all completely glued together with Aluminum joists... there is no air cavity in the ceiling for air to pass through, and no wood joists to screw any new Luane/plywood into. ...
Sorry for the assumption that there was an air space. I've noticed newer trailers have speakers mounted to the ceiling so I ass-u-me'd there was some space above.

Quote:
Originally Posted by Yellzee View Post
As for taking to the dealer... I think it will be 4-5K on a trailer worth maybe 9K... and I was looking to sell it and upgrade this year....
I'm invested in an older 23B with water issues. I'm new to the travel trailer forums. One trend that I have noticed is how quickly other posters are willing to tell people to go to the dealer or how the trailer they have water issues with is now scrap. It's just not very helpful information to someone trying to make the best of the situation they are in.

You put it well with your numbers. Going to a dealer for major repair on an older trailer is hardly ever a good option. Someone with DIY skills may be able to make it work for them, but not by taking it to a dealer. Sorry to go on.

Quote:
Originally Posted by Yellzee View Post
I really think if I could get a new roof panel it's the easiest fix (definitely not the cheapest!)... it appears to be just screwed down from above into the walls and it's one big piece.. guessing it can't weight more than a couple hundred pounds. I already have all the cabinets out. It's certainly the best way to do it.

...
I've seen videos that show the assembly of travel trailers. I know that repairs are much different than new builds, but it may be worth searching for a few assembly video links.

Keep us posted with more of your descriptions and some pictures. I know that I would appreciate the information. Good luck on your repairs. vic
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Old 05-07-2013, 09:04 PM   #9
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I will try to post some pics of tonights destruction here Vic. Pulled off alot of the roof membrane and man it is rotten. Where it isnt rotten the felt backing is very hard to pull off the luane. I propped up some support inside the trailer to help whats left of the roof while i was up there but it still seems ready to collapse. I was walking on a piece of 1/2 inch plywood i laid down to help spread the weight.
I still think an entirely new roof panel is the way to go if i can get it. I could winch it up to the rafters in the barn, back the trailer under it and lower it down. I did not get to the edges to see how the roof panel is actually fastened to the walls.

I did actually watch a few videos and it looked like when the inside was done they set the roof on. I couldn't find one that actually showed them attach it unfortunately.

Gave Jayco parts my vin tonight and hope to hear from them tomorrowClick image for larger version

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ID:	7793 about possibility of getting the new roof. (Shipping to canada a 19x 8 panel might be as much as the panel!)
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Old 05-07-2013, 09:12 PM   #10
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