Hello Guest

Author Topic: Fleetwood E3 Filon Roof Failure  (Read 421 times)

0 Members and 1 Guest are viewing this topic.

Offline KensAuto

  • Global Moderator
  • ****
  • Posts: 4142
  • Just call me Bounty.... always absorbing abuse
    • View Profile
Fleetwood E3 Filon Roof Failure
« on: December 19, 2017, 06:24:29 PM »
I don't have enough heartache in my life, so here goes another project. A couple years ago I redid the top of this pop-up, when the outer layer (Filon) failed, by sealing the cracks with foamboard sealant/adhesive and a few hundred dollars worth of color matched bedliner.
It failed within a year. I covered it with a canvas tarp and pushed it out of view.

The backstory: Fleetwood (Coleman) switched from aluminum as the roofing material, to a "spaceage" product called Filon around 2006-07. It's a super thin fiberglass like material that is super strong. It first becomes porous (pin holes) then shrinks and cracks. From the forums I've read, they warrantied a few just before selling their pop-up division to a different company. That company went bankrupt and closed their doors.

I recently found out that a different company (somerset rv) started building the same trailer and it actually carries the same name, Evolution 3. I called them to price a new roof and was told that the roofs wouldn't interchange, and that I wasn't the first person to call, regarding the same issue. He (Kevin) says that the roofs are different (even tho they are built on the same plans?) and even with fab skills, no way to modify to fit. No matter how hard I tried, I couldn't convince him to sell me one. He then said even if they would interchange, he had no way to sell me one. (I will add this company to the list...yeah, that list).
I want to document the rebuild here, whether it's a failure or a success, because I haven't seen one like this done on the web.
Underpaid and misunderstood since 2014

Offline KensAuto

  • Global Moderator
  • ****
  • Posts: 4142
  • Just call me Bounty.... always absorbing abuse
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #1 on: December 19, 2017, 06:24:55 PM »
Some pics of the original repairs in 2014
« Last Edit: December 19, 2017, 10:38:06 PM by KensAuto »
Underpaid and misunderstood since 2014

Offline stlaser

  • Registered
  • **
  • Posts: 4073
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #2 on: December 19, 2017, 06:35:08 PM »
Ken, with your mad fab skills can?t you just buy a couple of sheets of aluminum & find a local place with a brake & build your own? You would need heming dies to do a standing seam in the middle but it could be done pretty easy.....
Learn the rules like a pro so that you can break them like an artist -Pablo Picasso-

Offline TexasRedNeck

  • punching bag for moderator humor
  • Registered
  • **
  • Posts: 5707
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #3 on: December 19, 2017, 06:41:25 PM »
I was thinking a real thick layer of ShoeGoo


Sent from my iPhone using Tapatalk
Kids today don't know how easy they have it. When I was young, I had to walk 9 feet through shag carpet to change the TV channel.

Joshua 6:20-24

Offline KensAuto

  • Global Moderator
  • ****
  • Posts: 4142
  • Just call me Bounty.... always absorbing abuse
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #4 on: December 19, 2017, 06:42:18 PM »
I don't know about fab skills, but that was one of my thoughts. The way I'm leaning is towards using EPDM like most RVs. The main issue is that it's a sandwich style roof...thin panel inside, 1" styrofoam, then the Filon on top. No wood in the middle. To use epdm I think I would first have to glue some ply down to the foam with special adhesive (268.00/gallon), to give the rubber a base.....decisions, decisions

Charles  :knucklehead: !!!
Underpaid and misunderstood since 2014

Offline stlaser

  • Registered
  • **
  • Posts: 4073
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #5 on: December 19, 2017, 08:09:31 PM »
I vote for shoo goo
Learn the rules like a pro so that you can break them like an artist -Pablo Picasso-

Offline Sammconn

  • A Guy in the Sticks
  • Registered
  • **
  • Posts: 2505
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #6 on: December 19, 2017, 08:58:28 PM »
 
I vote for shoo goo
:likebutton:

Not sure which is the best way.
How would fibreglass fare?
And not to bring up the tac topper...
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline stlaser

  • Registered
  • **
  • Posts: 4073
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #7 on: December 19, 2017, 09:14:42 PM »
I vote for shoo goo
:likebutton:

Not sure which is the best way.
How would fibreglass fare?
And not to bring up the tac topper...

Oh you didn?t? :huh:
Learn the rules like a pro so that you can break them like an artist -Pablo Picasso-

Offline Bigdave_185

  • Raising Boys into Real Men!
  • Registered
  • **
  • Posts: 2072
    • View Profile
Fleetwood E3 Filon Roof Failure
« Reply #8 on: December 19, 2017, 09:25:03 PM »
Ken,

This is a site that I have found very helpful with the conversion of my enclosed 27 foot trailer to a camp trailer.  Poke around there and see if you find something helpful.  These guys are building trailers from nothing
Than I failed to provide a link
http://tnttt.com/

Sent from my iPhone using Tapatalk
« Last Edit: December 19, 2017, 09:30:09 PM by Bigdave_185 »

Offline nmeyer414

  • Global Moderator
  • ****
  • Posts: 3062
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #9 on: December 19, 2017, 09:29:45 PM »
Ken,

This is a site that I have found very helpful with the conversion of my enclosed 27 foot trailer to a camp trailer.  Poke around there and see if you find something helpful.  These guys are building trailers from nothing


Sent from my iPhone using Tapatalk

Is there a link you were wanting to put in this post dave..........?

I vote for shoo goo
:likebutton:

Not sure which is the best way.
How would fibreglass fare?
And not to bring up the tac topper...

Oh you didn?t? :huh:

Yes he did shawn, sam broke rules #1 & #2
Nate

Push a KIA or Prius into the ditch this winter if the opportunity arises........it'll build character for a suffering millennial! or if you see Donkey Kong in a Jetta expect a wedding in the works

Offline Bigdave_185

  • Raising Boys into Real Men!
  • Registered
  • **
  • Posts: 2072
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #10 on: December 19, 2017, 09:31:19 PM »
It?s been a long day lol


Sent from my iPhone using Tapatalk

Offline KensAuto

  • Global Moderator
  • ****
  • Posts: 4142
  • Just call me Bounty.... always absorbing abuse
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #11 on: December 19, 2017, 09:47:10 PM »
Alright, thanks Dave. Fiberglass is a no...the resin would eat the foam and putting a layer of wood first and then fiberglass might make it too heavy. It's already a pain for me to crank up...something to do with having a bad back or a weak mind, not sure which.

Sam, it' funny you mention *** ******.........my thoughts exactly.
Underpaid and misunderstood since 2014

Offline Flyin6

  • Administrator
  • *****
  • Posts: 18587
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #12 on: December 19, 2017, 10:33:48 PM »
Ken,

This is a site that I have found very helpful with the conversion of my enclosed 27 foot trailer to a camp trailer.  Poke around there and see if you find something helpful.  These guys are building trailers from nothing


Sent from my iPhone using Tapatalk

Is there a link you were wanting to put in this post dave..........?

I vote for shoo goo
:likebutton:

Not sure which is the best way.
How would fibreglass fare?
And not to bring up the tac topper...

Oh you didn?t? :huh:

Yes he did shawn, sam broke rules #1 & #2

We got rules?
Site owner    IS 6:8  Psalm 91 
NSDQ      Author: Distant Thunder

Offline Bigdave_185

  • Raising Boys into Real Men!
  • Registered
  • **
  • Posts: 2072
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #13 on: December 19, 2017, 10:41:40 PM »
Don?t group me in with rules


Sent from my iPhone using Tapatalk

Offline KensAuto

  • Global Moderator
  • ****
  • Posts: 4142
  • Just call me Bounty.... always absorbing abuse
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #14 on: December 19, 2017, 10:45:16 PM »

Here's what it looked like a year later.


Sent from my Pixel using Tapatalk

Underpaid and misunderstood since 2014

Offline KensAuto

  • Global Moderator
  • ****
  • Posts: 4142
  • Just call me Bounty.... always absorbing abuse
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #15 on: December 19, 2017, 10:51:57 PM »
Starting the tear down. First the long aluminum side rails. The only thing holding them down is urethane caulking, similar to windshield sealant. I had to use a torch to heat it up enough to break the bond.
Speaking of derailing.... you guys are worse than me!! (Maybe not)

Sent from my Pixel using Tapatalk

Underpaid and misunderstood since 2014

Offline Sammconn

  • A Guy in the Sticks
  • Registered
  • **
  • Posts: 2505
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #16 on: December 20, 2017, 10:40:59 AM »
Ken,

This is a site that I have found very helpful with the conversion of my enclosed 27 foot trailer to a camp trailer.  Poke around there and see if you find something helpful.  These guys are building trailers from nothing


Sent from my iPhone using Tapatalk

Is there a link you were wanting to put in this post dave..........?

I vote for shoo goo
:likebutton:

Not sure which is the best way.
How would fibreglass fare?
And not to bring up the tac topper...

Oh you didn?t? :huh:

Yes he did shawn, sam broke rules #1 & #2

Well, here's how I saw it.
We all were thinking it...
One of us was bound to mention it.
I think I'm the longest from being banned and or fired, so my turn.

Sorry Ken to junk up yet another thread.
But it's the way things roll around here.
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline kampfitt

  • Registered
  • **
  • Posts: 174
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #17 on: December 20, 2017, 11:21:34 AM »
We redid the inlaws 5th wheel rubber roof with this stuff.
http://richfieldtrailer.com/Dyco-Shield-and-Seal-890-Gallon-890G%7C1-302/
 Rolled it on just like rubber bedliner but white, sealed up the oud rubber roof and no more leaks!!  Needed 1gal and a quart to do 21ft roof.
08 EX-Cab D-Max 4X4 45 gal. aux tank Pull-Right Super Glide 5th hitch, Prvt. Pilot ,NRA Life Member , Michigan CPL Holder , T-Bird II Experimental Aircraft Builder, Electrician Flint Truck Asm.

Offline rpar86

  • Registered
  • **
  • Posts: 522
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #18 on: December 20, 2017, 03:12:17 PM »
How bout some of that As-Seen-On-TV FlexSeal stuff? The one that they use to seal up the bottom of the jon boat.
Ryan
2006 GMC 3500 6.6 CCLB SRW 4x4

Offline Flyin6

  • Administrator
  • *****
  • Posts: 18587
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #19 on: December 20, 2017, 05:02:06 PM »
Did someone just bring up that Tac-Topper?
Site owner    IS 6:8  Psalm 91 
NSDQ      Author: Distant Thunder

Offline stlaser

  • Registered
  • **
  • Posts: 4073
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #20 on: December 20, 2017, 05:31:46 PM »
Did someone just bring up that Tac-Topper?

Tac-Topper? What is that you speak of? :popcorn:
Learn the rules like a pro so that you can break them like an artist -Pablo Picasso-

Offline OldKooT

  • Registered
  • **
  • Posts: 1286
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #21 on: December 20, 2017, 05:44:34 PM »
I saw a guy redo one of those Ken..he used corrugated aluminum ..worked well enough, not super attractive LoL


Tac Topper, is that the legendary plywood bulletproof topper?
Norm

Are you a prepper?  "No, whats a prepper? I am just a mildly OCD farmer"

Offline Flyin6

  • Administrator
  • *****
  • Posts: 18587
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #22 on: December 20, 2017, 06:34:50 PM »
There will be no talk of that here!
Site owner    IS 6:8  Psalm 91 
NSDQ      Author: Distant Thunder

Offline cruizng

  • Registered
  • **
  • Posts: 472
  • Happy to be here.
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #23 on: December 20, 2017, 09:06:45 PM »
I didn't see nuttin'


Sent from my iPad using Tapatalk
Mike
2008 D-Max pretty stock except small lift, tires, and intake.

Offline KensAuto

  • Global Moderator
  • ****
  • Posts: 4142
  • Just call me Bounty.... always absorbing abuse
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #24 on: December 20, 2017, 09:48:59 PM »
Should I pull up some pics Norm? :wink
Underpaid and misunderstood since 2014

Offline nmeyer414

  • Global Moderator
  • ****
  • Posts: 3062
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #25 on: December 20, 2017, 10:46:45 PM »
Did someone just bring up that Tac-Topper?

HAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHA
Nate

Push a KIA or Prius into the ditch this winter if the opportunity arises........it'll build character for a suffering millennial! or if you see Donkey Kong in a Jetta expect a wedding in the works

Offline Bigdave_185

  • Raising Boys into Real Men!
  • Registered
  • **
  • Posts: 2072
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #26 on: December 21, 2017, 08:35:09 AM »
Should I pull up some pics Norm? :wink
Yes.


Sent from my iPhone using Tapatalk

Offline JR

  • Global Moderator
  • ****
  • Posts: 5825
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #27 on: December 26, 2017, 02:17:19 AM »
You can use Epoxy resin. That will not eat foam and is just a easy to use and find. I did a GM headliner with it and it worked great! Plus it stays flexible unlike poly resin.

I need to coat mine, but a new roof would be better.
Retired LEO  Lifetime NRA+  Outcast in Calif

"The tree of liberty must be refreshed from time to time with the blood of patriots and tyrants"

Thomas Jefferson

Offline nmeyer414

  • Global Moderator
  • ****
  • Posts: 3062
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #28 on: December 26, 2017, 09:13:16 AM »
You can use Epoxy resin. That will not eat foam and is just a easy to use and find. I did a GM headliner with it and it worked great! Plus it stays flexible unlike poly resin.

I need to coat mine, but a new roof would be better.

Didnt you just repair it like a year ago, has it gone to crap already?
Nate

Push a KIA or Prius into the ditch this winter if the opportunity arises........it'll build character for a suffering millennial! or if you see Donkey Kong in a Jetta expect a wedding in the works

Offline JR

  • Global Moderator
  • ****
  • Posts: 5825
    • View Profile
Re: Fleetwood E3 Filon Roof Failure
« Reply #29 on: December 26, 2017, 12:37:46 PM »
I repaired the leak which has held up fine. I still need to coat the entire roof though. 10 years old.
Retired LEO  Lifetime NRA+  Outcast in Calif

"The tree of liberty must be refreshed from time to time with the blood of patriots and tyrants"

Thomas Jefferson