Pop up roof rebuild jayco 1406

peter79 · 06-08-2016, 06:50 AM

First thanks for everyone input, you help was awesome.
I am going to show so pictures and what i did on my roof rebuild, this is in case other need help. Here is the camper that i got for $400.
Note, when adjusting cables cut 2x4 to 42" tall and position between the bottom of camper roof and top of bottom wall so that adjusting the cables or replacing cables is easier as this is the height of the door.

1ST pic, it is a 1996 jay jay series 1406 with a leaking roof and broken cables.

2nd pic, new structure, built form all pine board, sides are (2) 10"wide x 8ft long joined together with construction adhesion and frame plates. The cost beams are pine 2x4 every 16" on center. A/C cut out was reinforced with 2x4 pine to better support the weight of the unit.

3rd pic, is the underside once covered with 1/16 plywood sheet. (4) needed in total, plywood sheet over lap all sides. All bolts where replace with stainless steal and new stop cables were installed to ensure that over cranking can not occur and pushing the push rods out. These cable are to made form stainless steal.

4th pic, is showing that the door fits no problem and cables worked to stop form over cranking.

Next i will be sanding the corners smooth, cutting the access hole for the A/C unit and coating the roof and side panels in white flex seal liquid roof. The flex seal can be applied to the wood for waterproofing and sealing of the camper roof. I will post pictures of this once the product arrives.