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Foretravel Motorhome Forums => Foretravel Renovations => Topic started by: AncloteJoe on December 12, 2017, 10:09:30 am

Title: Subfloor issues - preparing for vinyl flooring
Post by: AncloteJoe on December 12, 2017, 10:09:30 am
 I am replacing the flooring with floating vinyl. When I removed the carpeting, I found a place behind the passengers seat where the subfloor is bulged up about half an inch.  I drilled a hole through it to check it and found no signs of delamination of the plywood or any signs of moisture. Has anyone run into this? How did you fix it? What would have caused this?

Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: gracerace on December 12, 2017, 10:19:21 am
Would that be where one of the upright walls are in the basement ?
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: Blinded04 on December 12, 2017, 10:47:55 am
If yours is like mine, there is a gigantic steel plate underneath that plywood across the entire floor.  Wherever there is a screw through the plywood, there is also a hole drilled through the steel plate.

If a prior owner were to have added an accessory, seat belts, couch, etc., or replaced that piece of plywood in the past, and didn't put the screw back in the exact same place (and didn't drill a new hole), any new screw would hit the steel plate, and could actually lift the plywood off the ground as you "screwed it further in" if it wasn't firmly secured in several other places.  Find your screws in the problem area, and back them out a bit - if the plywood starts lowering, that's your problem.  Might even be the passenger seat.
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: AncloteJoe on December 12, 2017, 11:07:14 am
Would that be where one of the upright walls are in the basement ?

This is forward of the vertical wall. I see a double row of bolt heads in going across the floor I assume thats where the bulkhead is. This is forward of that.

If yours is like mine, there is a gigantic steel plate underneath that plywood across the entire floor.  Wherever there is a screw through the plywood, there is also a hole drilled through the steel plate.

I drilled through the plywood in the center of the bulge and around the corners and below it is blue foam insulation. Where would the steel plate be?
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: Don & Tys on December 12, 2017, 11:16:04 am
Perhaps yours is different, but on ours the ¼" steel plate only covers the are where the step cover is stowed when retracted. The area behind and under the passenger's seat is not covered by this plate. However, there is square tubular steel framing at intervals under the plywood throughout, and screws through the plywood that are not penetrating the tubing could dome the plywood. The vertical bulkheads below can be located by the bolt heads countersunk in the subfloor with carpet removed, if there hasn't been plywood added to the original subfloor. If the issue isn't because of a void in the plywood in the subfloor or glue failure, a half inch sounds pretty extreme, I would wonder if there had been some collision repair. Another possibility, is rust jacking on the frame underneath, but I can't imagine that there wouldn't be signs of past water intrusion. Let us know what you figure out. To address the issue, the offending plywood could be cut out with a carefully calibrated depth of cut over the top of two adjacent segments the steel framing (so that a patch piece could be supported by half of the width of the 1 ½" square tubing below). Not that easy, but doable by using the right tools and making the cuts precisely the first time. But first, try to discover the cause and fix it! If there is steel tubing below the middle of the dome and the dome isn't hollowed out, some screws to clamp it down flat is a possibility...
Don
If yours is like mine, there is a gigantic steel plate underneath that plywood across the entire floor.  Wherever there is a screw through the plywood, there is also a hole drilled through the steel plate.

If a prior owner were to have added an accessory, seat belts, couch, etc., or replaced that piece of plywood in the past, and didn't put the screw back in the exact same place (and didn't drill a new hole), any new screw would hit the steel plate, and could actually lift the plywood off the ground as you "screwed it further in" if it wasn't firmly secured in several other places.  Find your screws in the problem area, and back them out a bit - if the plywood starts lowering, that's your problem.  Might even be the passenger seat.
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: wayne m on December 12, 2017, 01:51:52 pm
perhaps the plywood has become delaminated in that area?
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: kenhat on December 12, 2017, 02:52:30 pm
Whatever it turns out to be after repair be sure the floor meets perfectly. Every little imperfection will transmit right through the vinyl floor. Carpet can hide a lot of those sins but not vinyl. Speaking from experience here...

see ya
ken
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: Jack Lewis on December 12, 2017, 04:12:17 pm
I'm not a fan of the luxury vinyl.  I put it in my previous RV and each tiny imperfection showed, after I spent hours in preparation.  You will need a mirror smooth floor.  This week I saw a new product I was told they just started carrying at Lowe's, 100% water proof click together flooring. From the specifications on the Lowes site, 100% waterproof construction -- ideal for kitchens, baths, and basements  I am going to check with the mfg about temperature recommendations.  Shop Cali Bamboo Cali Vinyl 10-Piece 7.125-in x 48.03-in Gray Ash Locking... (https://www.lowes.com/pd/Cali-Bamboo-Cali-Vinyl-10-Piece-7-125-in-x-48-03-in-Gray-Ash-Locking-Luxury-Commercial-Residential-Vinyl-Planks/1000224357)
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: evantwheeler on December 12, 2017, 09:19:51 pm
I'm not a fan of the luxury vinyl.  I put it in my previous RV and each tiny imperfection showed, after I spent hours in preparation.  You will need a mirror smooth floor.  This week I saw a new product they just srarted carrying at Lowe's, 100% water proof click together flooring.  I will update this when I see the product again.

Was it Lifeproof vinyl plank flooring?  It has a PVC core and vinyl laminate on top.  Seems to be bulletproof and low maintenance.  This will be the product I put in during my remodel. 

LifeProof Multi-Width x 47.6 in. Seasoned Wood Luxury Vinyl Plank Flooring... (https://www.homedepot.com/p/LifeProof-Multi-Width-x-47-6-in-Seasoned-Wood-Luxury-Vinyl-Plank-Flooring-19-53-sq-ft-case-I114813L/300461633)

Regarding the hump, I don't have any good advice as to the cause.  My floors are stripped to the plywood and I do not see anything that looks like what you've shown on my floor.  Regardless of flooring material selected, save carpet, you will likely be sorry for not solving the bulge issue if you lay over top of it. 
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: evantwheeler on December 12, 2017, 09:23:20 pm
I am replacing the flooring with floating vinyl. When I removed the carpeting, I found a place behind the passengers seat where the subfloor is bulged up about half an inch.  I drilled a hole through it to check it and found no signs of delamination of the plywood or any signs of moisture. Has anyone run into this? How did you fix it? What would have caused this?



What is that light horizontal line running left to right?  It almost looks like someone has replaced that section of plywood and that the seam has been caulked/filled? If it has been replaced, they must not have re-installed correctly.  My floor is full sheets of plywood, 4'x8' running the width of the unit wall to wall.  The seams run left to right, wall to wall looking towards the front or back of the unit.  I have no seams running fore/aft.
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: Neal Pillsbury on December 12, 2017, 10:15:57 pm
I am replacing the flooring with floating vinyl. When I removed the carpeting, I found a place behind the passengers seat where the subfloor is bulged up about half an inch.  I drilled a hole through it to check it and found no signs of delamination of the plywood or any signs of moisture. Has anyone run into this? How did you fix it? What would have caused this?


Rick,
Lots of interesting, random speculation, but between the only two owners of "Princess", the answer to where the "Hump" came from, is that it was caused by the front tire, passenger side, pressing hard against the overhead of the wheel well for extended periods of time as the coach tried to maintain level in our driveway in NH.  And that is something that FT denied — first as a problem and — second as anything that the coach suspension system design caused and — third anything that they felt any responsibility for addressing — even though FT MCC friends have relayed that they (FT) did patch several (perhaps as many as a dozen) floors that showed these symptoms, over the years.  There are many that will say that the coaches of this era will not be harmed when they are aired down and the tires press hard into the wheel well overhead.  I believe that is horsepuckey.  Somewhere along, sometime in 2001 but with certainty in 2002, FT changed frame and suspension dimensions. Thereafter, tires no longer touch wheel well overheads when the coach is "aired down".  In the susceptible years (1996 thru 2000 with certainty), I believe that there are many variables and when the variables happen to line up, flooring damage will occur.  Variables examples include side to side slope, end to end slope, front end vs. rear end slope ratio (greater slope in the front than in the back with a front end being at a higher elevation than the rear is the really bad combination to avoid), humidity, temperature, time of exposure to tire pressure on the overhead surface, particular coach plywood variables/characteristics (e.g - type of plywood, grain, finish, east-west vs. north-south panel orientation, etc.), perhaps insulation foam variables, to mention a few.

As you probably know, the "Hump" comes and goes with humidity — or at least it used to when we owned the coach.  It would be good for many months and then all of a sudden, it would show up for a while, usually for a few days or maybe a week or so.  It was usually after the coach had been inactive and shut up during humid and/or cold weather.  Eventually, I correlated it pretty precisely to inactivity and high humidity. 

The behavior puzzled me for years until we had close friends park a 2000 U320 40' FT in the same NH driveway location and they developed an identical bulge in their floor, over the course of a week (+) stay.  Now, because we didn't remove and dissect any plywood sections, I don't know if these were delamination events or just deformations of the plywood but it was identical in both coaches and both leveling systems pushed their front passenger side tire hard into the overhead, enough to be able to see the physical deformations in the wheel well overhead, once you got under the coach.  I documented all of this pretty extensively on the Forum in "to Dump or not to Dump" discussion threads.  For Example: (and there are others)

Dump Air Bags or Not? (http://www.foreforums.com/index.php?topic=14319.msg82845#msg82845)
Tire clearance issue (http://www.foreforums.com/index.php?topic=17418.msg116181#msg116181)
Controversey Over Leveling Coach (http://www.foreforums.com/index.php?topic=23268.msg180454#msg180454)

After it once occurred, our friend's FT coach, exhibited the same "on again, off again Hump" appearance behavior for the rest of the time that they owned their coach (many years, maybe ten or so). 

Our friends subsequently met someone that had a coach of the same general age (a 1999 U295 40'), that claimed to have injected glue into his delamination void thru a saw kerf and then lay in a pattern of wood screws to draw the floor back to level.  In at least three cases that I am aware of, FT made a lot more work of it, removing a large section of plywood flooring, sawing out that section at a dimension that allowed the sharing of 1/2 the width of the underlying floor frame members (just as Don has suggested), and then replacing the removed section with fresh plywood.

Because we always intended to have (keep) carpet in the living room, we never addressed it further than trying to get FT to show some responsibility for the anomaly and to offer a solution.  They would gladly do the work for us but would not accept any responsibility or help in any way in mitigating the cost.  They never admitted (to us at least) knowing why or how it happens.  They admitted to having done several replacements, suggesting to us that it had always been abusive things that owners had done to their coaches.

HTH,
Neal
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: Don & Tys on December 12, 2017, 10:36:30 pm
What is that light horizontal line running left to right?  It almost looks like someone has replaced that section of plywood and that the seam has been caulked/filled?
Interesting thought that would make sense, but it should be obvious. The plywood used in the original build does run the full width, so if there is a longitudinal seam in the plywood, that wood be some sort of patch. If that is the case and it was cut a tad to large, that would explain the bulge. I thought that line was residue from a joined piece of carpet padding. Did the coach have the dense and heavy black vinyl pad in the cockpit area that stopped just behind the passenger chair? If not, more evidence of previous repair work. In any case, unless screws that are dead ending into the steel framing are the cause of the bulge and you can remedy the bulge by backing them out and pre-drill and reattach, you will have to do some surgery to level it. Careful planning is the key. If there is a patch and you can define the extent of it, I believe removing the entire patch is called for and would likely be easier than a surgical cut of just the bulge and then making a plug that is supported from underneath to create a subfloor as solid as the original. You might also consider adding a ¼" or ⅜" layer of sanded plywood over the entire flooring project as many have done. A fair amount of work, but it can make the finished floor installation better, particularly if going over the area of the original kitchen wood flooring which always leaves some damaged areas that need to be addressed. In my case, I only added the layer of ¼" plywood in the cockpit under the luxury vinyl tile, and that was just to make it level with the bamboo that runs throughout the rest of the coach. Good luck on your project, it sounds like a head scratcher, but where there is a will, there is a way!
Don
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: Jack Lewis on December 12, 2017, 10:53:47 pm
Thanks Neal for the post, made me go back and read the entire post that you gave a link to.  Very interesting, as I plan to install Shop Cali Bamboo Cali Vinyl 10-Piece 7.125-in x 48.03-in Gray Ash Locking... (https://www.lowes.com/pd/Cali-Bamboo-Cali-Vinyl-10-Piece-7-125-in-x-48-03-in-Gray-Ash-Locking-Luxury-Commercial-Residential-Vinyl-Planks/1000224357) which is 100% water proof, sold by Lowes.  I'll watch this issue in the meantime.  I live on a hill and often level out in front of my home, bottoming out the drivers side rear dual.  Again thank you, I am continually reminded of the depth and knowledge of this forum's members.  Also, just because the rv has only had you and another during its life doesn't mean that FT may not have addressed this issue before you took delivery.
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: craneman on December 12, 2017, 11:08:18 pm
What are the round stops on the arms doing if the tires hit first?
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: Don & Tys on December 12, 2017, 11:59:34 pm
Well Neal, that explains it. Obvious now that you remind me of those threads. It is because I read those threads so long ago that I do my best to never let the tires push on the bottom of the floor above the wheel well. When we level, I always level manually by bringing the low side up first, and if that isn't enough I always lower the high corner as little as possible to allow for some settling. If it looks like the tire is close to touching after all that, I take some material and use it like a feeler gauge to insure that the tire isn't pressing. Those round puck stops will keep the tires from touching with the air dumped only on a fairly level surfaces. The solid beam axles cause the tires to approach the bottom of the floor on a surprisingly steep angle, meaning that the outer edge of the tire touches first, which concentrates the contact area. I have considered how I might make those puck shaped stops thicker by attaching a urethane bushing, so that the decreased travel doesn't result in more aggressive contact on bad roads, but I haven't acted on it yet. I would like to be able to dump the air in near level situations without fear of creating a bulging floor.
Don
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: jcus on December 13, 2017, 12:08:30 am
Rick,
Lots of interesting, random speculation, but between the only two owners of "Princess", the answer to where the "Hump" came from, is that it was caused by the front tire, passenger side, pressing hard against the overhead of the wheel well for extended periods of time as the coach tried to maintain level in our driveway in NH.  And that is something that FT denied — first as a problem and — second as anything that the coach suspension system design caused and — third anything that they felt any responsibility for addressing — even though FT MCC friends have relayed that they (FT) did patch several (perhaps as many as a dozen) floors that showed these symptoms, over the years.  There are many that will say that the coaches of this era will not be harmed when they are aired down and the tires press hard into the wheel well overhead.  I believe that is horsepuckey.  Somewhere along, sometime in 2001 but with certainty in 2002, FT changed frame and suspension dimensions. Thereafter, tires no longer touch wheel well overheads when the coach is "aired down".  In the susceptible years (1996 thru 2000 with certainty), I believe that there are many variables and when the variables happen to line up, flooring damage will occur.  Variables examples include side to side slope, end to end slope, front end vs. rear end slope ratio (greater slope in the front than in the back with a front end being at a higher elevation than the rear is the really bad combination to avoid), humidity, temperature, time of exposure to tire pressure on the overhead surface, particular coach plywood variables/characteristics (e.g - type of plywood, grain, finish, east-west vs. north-south panel orientation, etc.), perhaps insulation foam variables, to mention a few.

As you probably know, the "Hump" comes and goes with humidity — or at least it used to when we owned the coach.  It would be good for many months and then all of a sudden, it would show up for a while, usually for a few days or maybe a week or so.  It was usually after the coach had been inactive and shut up during humid and/or cold weather.  Eventually, I correlated it pretty precisely to inactivity and high humidity. 

The behavior puzzled me for years until we had close friends park a 2000 U320 40' FT in the same NH driveway location and they developed an identical bulge in their floor, over the course of a week (+) stay.  Now, because we didn't remove and dissect any plywood sections, I don't know if these were delamination events or just deformations of the plywood but it was identical in both coaches and both leveling systems pushed their front passenger side tire hard into the overhead, enough to be able to see the physical deformations in the wheel well overhead, once you got under the coach.  I documented all of this pretty extensively on the Forum in "to Dump or not to Dump" discussion threads.  For Example: (and there are others)

Dump Air Bags or Not? (http://www.foreforums.com/index.php?topic=14319.msg82845#msg82845)
Tire clearance issue (http://www.foreforums.com/index.php?topic=17418.msg116181#msg116181)
Controversey Over Leveling Coach (http://www.foreforums.com/index.php?topic=23268.msg180454#msg180454)

After it once occurred, our friend's FT coach, exhibited the same "on again, off again Hump" appearance behavior for the rest of the time that they owned their coach (many years, maybe ten or so). 

Our friends subsequently met someone that had a coach of the same general age (a 1999 U295 40'), that claimed to have injected glue into his delamination void thru a saw kerf and then lay in a pattern of wood screws to draw the floor back to level.  In at least three cases that I am aware of, FT made a lot more work of it, removing a large section of plywood flooring, sawing out that section at a dimension that allowed the sharing of 1/2 the width of the underlying floor frame members (just as Don has suggested), and then replacing the removed section with fresh plywood.

Because we always intended to have (keep) carpet in the living room, we never addressed it further than trying to get FT to show some responsibility for the anomaly and to offer a solution.  They would gladly do the work for us but would not accept any responsibility or help in any way in mitigating the cost.  They never admitted (to us at least) knowing why or how it happens.  They admitted to having done several replacements, suggesting to us that it had always been abusive things that owners had done to their coaches.

HTH,
Neal
Agree, had a 99 320 that would rest on tires. Never thought about it, but had an all tile coach with some cracks in tile?
Now have an 03 that even with bags dumped and 0 air pressure, about 2 inches between floor and tire.
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: John S on December 13, 2017, 06:20:19 am
It was the 02 model year that they raised the house 2 inches.  It caused one step to be a bit taller the the others and they got complaints so in 03/04 went to that folding metal step. I saw Gary Omels coach after he had a front blowout and he had a hole thru the carpet floor behind the passenger seat from it.
Title: Re: Subfloor issues - preparing for vinyl flooring
Post by: AncloteJoe on December 13, 2017, 12:58:34 pm
Thanks Neal for the write-up. Now we know where it comes from. It makes sense although the bulge is more towards the center of the coach, I can see putting upward pressure on the floor near the wall could buckle the center of the floor.  I have opened the bulge as shown in the attached picture using a series of criss-cross cuts. I found no signs of water intrusion anywhere here also, no sign of the plywood delaminating. it was fully intact, just bulged.  Surprisingly, the flooring is NOT 3/4" like everyone assumes it looks to be 7/16 or 13/32. not real heavy.  As you walk on it, it flexes in spots and you can hear air being forced up through the cracks. I lifted up one of the cut  sections to peer under it and it appears that the plywood was attached to the foam insulation layer with an adhesive which obviously has given way. 

So, what to do about it.

after cutting it, I laid a heavy weight on in to see if it will lay back down. If I can get it to lay back down, I will glue it back in place. I am not sure what adhesive to use. If anyone knows a good adhesive that will not adversely react with(melt) the foam insulation underneath and will seal the cuts I made in the plywood let me know.  The other thought I had was to cut a piece of sheet metal and overlay that section. Any other suggestions?