Post by: KensAuto on December 19, 2017, 06:24:29 PM
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.
Post by: KensAuto on December 19, 2017, 06:24:55 PM
(https://uploads.tapatalk-cdn.com/20171220/969fe9586617391ae23da29376bae8ba.jpg)(https://uploads.tapatalk-cdn.com/20171220/4ea507d9f94dd5b7579d5f2686fdfcf0.jpg)(https://uploads.tapatalk-cdn.com/20171220/4fe0f0745f46eb3ab65e74f97b8b480e.jpg)(https://uploads.tapatalk-cdn.com/20171220/7298656e846ec7526f30bfde0e9c1f68.jpg)(https://uploads.tapatalk-cdn.com/20171220/14810d8252e587096149b5bd2d525994.jpg)(https://uploads.tapatalk-cdn.com/20171220/e3c88c7871aa8b8758a72f72e712227e.jpg)
Post by: stlaser on December 19, 2017, 06:35:08 PM
Post by: TexasRedNeck on December 19, 2017, 06:41:25 PM
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Post by: KensAuto on December 19, 2017, 06:42:18 PM
Charles :knucklehead: !!!
Post by: stlaser on December 19, 2017, 08:09:31 PM
Post by: Sammconn 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...
Post by: stlaser 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:
Post by: Bigdave_185 on December 19, 2017, 09:25:03 PM
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/
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Post by: Nate 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
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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
Post by: Bigdave_185 on December 19, 2017, 09:31:19 PM
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Post by: KensAuto on December 19, 2017, 09:47:10 PM
Sam, it' funny you mention *** ******.........my thoughts exactly.
Post by: Flyin6 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
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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?
Post by: Bigdave_185 on December 19, 2017, 10:41:40 PM
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Post by: KensAuto on December 19, 2017, 10:45:16 PM
Here's what it looked like a year later.
(https://uploads.tapatalk-cdn.com/20171220/a102188eac3a2779834f4f4f099f77b4.jpg)(https://uploads.tapatalk-cdn.com/20171220/565f51431137957f3a97f561423b250c.jpg)
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Post by: KensAuto on December 19, 2017, 10:51:57 PM
Speaking of derailing.... you guys are worse than me!! (Maybe not)(https://uploads.tapatalk-cdn.com/20171220/9f988b2a4998d867735c87791ef5044a.jpg)
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Post by: Sammconn 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.
Post by: kampfitt on December 20, 2017, 11:21:34 AM
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.
Post by: rpar86 on December 20, 2017, 03:12:17 PM
Post by: Flyin6 on December 20, 2017, 05:02:06 PM
Post by: stlaser 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:
Post by: OldKooT on December 20, 2017, 05:44:34 PM
Tac Topper, is that the legendary plywood bulletproof topper?
Post by: Flyin6 on December 20, 2017, 06:34:50 PM
Post by: cruizng on December 20, 2017, 09:06:45 PM
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Post by: KensAuto on December 20, 2017, 09:48:59 PM
Post by: Nate on December 20, 2017, 10:46:45 PM
Did someone just bring up that Tac-Topper?
HAHAHAHAHAHAHAHAHAHAHAHAHAHAHAHA
Post by: Bigdave_185 on December 21, 2017, 08:35:09 AM
Should I pull up some pics Norm? :winkYes.
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Post by: JR on December 26, 2017, 02:17:19 AM
I need to coat mine, but a new roof would be better.
Post by: Nate 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?
Post by: JR on December 26, 2017, 12:37:46 PM
Post by: KensAuto on April 29, 2020, 09:16:13 PM
So, after stripping the thin layer of Filon off, I realized how bad the foam layer was. It was 2 long sheets of cheap white styrofoam...lighter than a gas station cup. I proceeded to cut all of the foam out and replace it.
I have a hard time describing how difficult that was, using an oscillating tool, separating it from the thin plywood layer (inside ceiling) without destroying the wood. Also very messy.
To be able to support the thin plywood i cut some 2x4 rafters and slid them into aluminum channels on the inside perimeter then a platform for me to kneel on from above.
Post by: KensAuto on April 29, 2020, 09:28:03 PM
I don't remember the brand of foam safe adhesive I used but it was in a 3 gallon bucket, and I used all of it. I then used partially filled sandbags to keep pressure down on the foam until dry, only doing 1 panel a day. I could only put so much weight on it without causing it to bow downwards.
After all the panels were glued, I used some loctite brand foam adhesive to fill in any gaps and used it like Bondo in some areas.
By this point I was pretty frustrated with the whole thing and didn't take many pics.(https://uploads.tapatalk-cdn.com/20200430/e2a5c9c558a5ef69f6c400a1fb239533.jpg)
Post by: Flyin6 on April 29, 2020, 10:24:16 PM
Post by: Nate on April 29, 2020, 10:52:19 PM
Post by: KensAuto on April 29, 2020, 11:33:01 PM
At first I tried to replace just the worst sections, then eventually stripped all of it.(https://uploads.tapatalk-cdn.com/20200430/64a7facb2bbab70f77b4a83abbd34010.jpg)(https://uploads.tapatalk-cdn.com/20200430/1fbd3b3a0dd738d9fce19e1552e92970.jpg)(https://uploads.tapatalk-cdn.com/20200430/33f684ec38ac51605bd933fbe0d7b49e.jpg)
Post by: KensAuto on April 29, 2020, 11:35:13 PM
Post by: KensAuto on April 29, 2020, 11:45:57 PM
I put it on the back burner again until one day when my friends son stopped by. He worked on tractor trailers for a large super market. He told me they outsourced damaged trailers to a shop that had a large roll of aluminum that they would back a trailer under, roll out whatever length needed to repair the roof, and cut it to length.
So I ended up with this. 8'w by 16' long.
Got it for cost...180 bucks(https://uploads.tapatalk-cdn.com/20200430/de39de299bdb5e00da481e06705f3b66.jpg)
Post by: KensAuto on April 29, 2020, 11:58:18 PM
Again, it's imperative that I get all 3 layers to bond since it's so, well, flimsy.
(1/8" plywood, 1" foam, and the aluminum sheet) I was able to walk on the original without it flexing so that's what I'm trying to replicate.
I made some different rafters for temporary support, cutting and planing 2x4s to have an upwards arch. Using sandbags again, I don't want it to sag and hold water. (https://uploads.tapatalk-cdn.com/20200430/2877f16ec48ab8c85bbd5e87d8ef26a0.jpg)
Post by: KensAuto on April 30, 2020, 12:02:27 AM
Downside is that I won't be able to cover very much area before it tacks up. (https://uploads.tapatalk-cdn.com/20200430/361bd6350d285fa986dad3b394bd1a50.jpg)
Post by: KensAuto on April 30, 2020, 12:08:35 AM
Post by: KensAuto on April 30, 2020, 12:20:35 AM
Next hurdle was to try and glue it down in sections. There's no way I could do it all at once without messing something up.
We started by laying it flat. Then I clamped a 2x4 to one end. A pulley was hung from the roof above the opposite end then a rope ran from the 2x4 up through the pulley and back down to a tie off point. The sheet was basically rolled halfway back over itself but held high enough not to fold in half.
Hmm. No pics of that cluster****
...so basically glued down 1/2 of the sheet, added sand bags, and let dry for 2 days. (https://uploads.tapatalk-cdn.com/20200430/cda0fab57f1b9fcbef59b14058eacabc.jpg)
Post by: KensAuto on April 30, 2020, 12:28:25 AM
At this point I realized how hard this aluminum was to bend. .. with a buddy helping me we got the rear folded over. It was a battle. It looks terrible, unless you like that hammered sheet metal look.(https://uploads.tapatalk-cdn.com/20200430/9464c3a62a42e6afb89c29b00ac26283.jpg)(https://uploads.tapatalk-cdn.com/20200430/60ff193282fd28c23c4ee6ee442ffdd9.jpg)
Post by: KensAuto on April 30, 2020, 12:38:52 AM
Anyway, not going to go through that again on the front. This guy knows a thing or two about annealing metal, especially copper. How much different can it be to soften aluminum? You just soot it up with acetylene and burn it off with some heat right?
Any knucklehead could do that.
I didn't take a pic of it before I cut it off this morning, but here it is after. So much for not having any seams. Urrr(https://uploads.tapatalk-cdn.com/20200430/494d4c8611ba829772f9ae06684ac94a.jpg)(https://uploads.tapatalk-cdn.com/20200430/d5d8b3e2a2c54151e28c202f26d2654f.jpg)
(https://uploads.tapatalk-cdn.com/20200430/34038df220029f41f35db9cf2368fe0c.jpg)
Post by: wyorunner on April 30, 2020, 01:56:22 AM
Post by: TexasRedNeck on April 30, 2020, 08:03:52 AM
Ken I’d have figured you’d have fabbed a bender with some heavy angle iron
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Post by: KensAuto on April 30, 2020, 09:31:49 AM
Ken, I thought you had a toy hauler? I know this was in the shop, but aside from moving it out of the shop, what’s your plan with it? Good work though!My first trailer. Bought it new. Fun for short trips, but it's going away as soon as it's done.
Charles, not sure how to reply at this point in time. Can't find a middle finger emoji.
Post by: Flyin6 on April 30, 2020, 07:00:16 PM
Ken, I thought you had a toy hauler? I know this was in the shop, but aside from moving it out of the shop, what’s your plan with it? Good work though!My first trailer. Bought it new. Fun for short trips, but it's going away as soon as it's done.
Charles, not sure how to reply at this point in time. Can't find a middle finger emoji.
And you won't
I'm watchin' U!
;-)
Post by: Flyin6 on April 30, 2020, 07:01:59 PM
I decided to go ahead and trim off the back and sides, especially since it was at jugular height (a couple close calls).You need some mil-spec grade "bend-all"
At this point I realized how hard this aluminum was to bend. .. with a buddy helping me we got the rear folded over. It was a battle. It looks terrible, unless you like that hammered sheet metal look.(https://uploads.tapatalk-cdn.com/20200430/9464c3a62a42e6afb89c29b00ac26283.jpg)(https://uploads.tapatalk-cdn.com/20200430/60ff193282fd28c23c4ee6ee442ffdd9.jpg)
I'll see if I have some
Maybe Tate sells it???
Post by: EL TATE on May 01, 2020, 12:50:08 PM
Post by: Flyin6 on May 01, 2020, 04:06:25 PM
in 5 gal buckets sir. along with grizzly greaseKen...???
You listening?
Thanks Tate!
Post by: KensAuto on May 01, 2020, 10:22:27 PM
Post by: stlaser on May 01, 2020, 10:36:09 PM
Post by: Flyin6 on May 02, 2020, 10:19:30 AM
What are you guys going on about?Proper method for bending high strength aluminum...
I thought you'd know all about it, but then I thought, you're not in aviation
So
Smear "Bend-All" on the area you wish to bend the high strength aluminum. Then aneal as you would normally. Then quickly make your proper bend and just like
that
It's all pretty and done!
Post by: KensAuto on May 02, 2020, 01:10:16 PM
When I Google that word all sorts of interesting stuff comes up...and they don't have anything to do with metal!
Regardless, I'm past that point. I cut out the warped piece and the rest went back to laying flat. I took the largest trimming, 15" long , and heated the entire piece with a rosebud.
That worked and was easily bent into a 90 like butter.
Here it is after annealing, next to the warped piece.(https://uploads.tapatalk-cdn.com/20200502/8853119e01c7346ae07d7d1778fe23ee.jpg)
Post by: Flyin6 on May 03, 2020, 06:31:04 PM
Post by: KensAuto on May 03, 2020, 10:04:27 PM
After about 80 rivets and using highly specialized lead filled weights, the front is almost done.
Maybe Elon will give me a job now...
... probably not.... looks more like a Boeing rivet job.(https://uploads.tapatalk-cdn.com/20200504/e60a62142c132674c1c792b31848c2d4.jpg)(https://uploads.tapatalk-cdn.com/20200504/dedc72fcbde61e7834e17a4a1fc41d30.jpg)(https://uploads.tapatalk-cdn.com/20200504/dcdf365b94a64b67bcaf70a1441f1c82.jpg)(https://uploads.tapatalk-cdn.com/20200504/1f06f1518562689ab3ec22f603231cc7.jpg)
(https://uploads.tapatalk-cdn.com/20200504/b77ae1993fb76a2e4ce1d6093aca4959.jpg)
Post by: Bigdave_185 on May 03, 2020, 10:26:34 PM
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Post by: KensAuto on May 03, 2020, 11:22:16 PM
Looks good, that is a whole mess of deka batteries. What do you have those forAs long as I can clean the adhesive off of them I plan on selling them to customers.
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Post by: Sammconn on May 04, 2020, 10:18:28 AM
:beercheers:
Post by: KensAuto on May 04, 2020, 03:31:07 PM
Post by: KensAuto on May 07, 2020, 09:40:07 PM
Post by: KensAuto on May 11, 2020, 09:48:20 PM
Post by: JR on May 11, 2020, 09:54:55 PM
Post by: KensAuto on May 16, 2020, 10:32:27 PM
Post by: Bob Smith on May 17, 2020, 12:27:37 AM
Post by: KensAuto on May 17, 2020, 01:42:09 AM
Looks really good KenThanks Bob, and JR.
Post by: TexasRedNeck on May 17, 2020, 07:48:40 AM
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Post by: oklawall on May 17, 2020, 05:07:56 PM
Post by: KensAuto on May 22, 2020, 09:59:19 PM
Post by: KensAuto on May 22, 2020, 10:01:13 PM
Post by: KensAuto on May 22, 2020, 10:06:57 PM
I almost made some out of aluminum but honestly I'm just over it with this pos.
(https://uploads.tapatalk-cdn.com/20200523/3c524508acc812d36ec62502da26860b.jpg)(https://uploads.tapatalk-cdn.com/20200523/d1bf7ca047ecd4fd3f70c08bfe43c6c3.jpg)(https://uploads.tapatalk-cdn.com/20200523/4db819f23e01dbfe52f0b4deb8558977.jpg)
Post by: KensAuto on May 22, 2020, 10:13:15 PM
Post by: KensAuto on May 22, 2020, 10:26:22 PM
They are about 12 feet long, and the only things keeping them in place is that they are glued down with something similar to windshield adhesive, and they kinda "snap" on to the corner pieces.
What's worse is that they're designed to accept roof racks, rated for a couple hundred pounds.
I had one come loose a few years ago and had to redo it, and there's stories on the web of guys losing their cargo, along with the rails, on the highway. Scary if you ask me.
I used 4 tubes of windshield urethane on those rails and some screws on the ends to be safe.
Ta da!(https://uploads.tapatalk-cdn.com/20200523/82b0afddb427967634c271ab1f29f309.jpg)(https://uploads.tapatalk-cdn.com/20200523/ea554d81377865a6a6892c18055272e0.jpg)(https://uploads.tapatalk-cdn.com/20200523/92e3f14579c6650813e48340f1a5122a.jpg)
Post by: JR on May 23, 2020, 02:20:29 PM
Post by: EL TATE on May 26, 2020, 10:55:35 AM