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Topic: Fixed the delaminated area and crack on the roof for $60 (Read 1063 times) previous topic - next topic

Fixed the delaminated area and crack on the roof for $60

Greetings fellow FT lovers,

The roof of my 1991 U225 is somewhat of an oddity. There is a large patch over the dinette seat. Looking at it, it appeared to be the same size as the skylight over the shower. When measured, it turned out to be a little bigger than the skylight frame. Best guess at this point is there was once a skylight there, which was later removed, although that doesn't make much sense.

While whomever patched used a decent adhesive, a crack developed at the corner under the patch and began spreading across the roof towards the front A/C unit. The crack also led to about 70% of the patch delaminating. After pulling and tossing the front A/C (was replacing it anyway), was relieved to find the crack did not extend all the way to the opening.

Debated on how to approach this; in the end, decided as no one goes up there I wasn't going to get fancy and would settle for a proper repair, even if the cosmetics weren't up to professional standards. Am planning to paint the roof soon, as the only gelcoat left up there is under the A/C units.

So - how to relaminate that area and seal it for good? Dug around some, then talked to my boating friend with my solution. The verdict was good. I headed down to the local hardware store, bought three tubes of 3M 5200 Marine adhesive/sealant ($18 each), and a 1/2 dozen stainless steel plate washers and 3/4" screws.

The 5200 is amazing stuff - and permanent. That panel is not coming loose again. What we did was take the suction cup from my Tripmaker GPS (adapt and improvise  ;D), coated the suction cup with some Vaseline, and were now able to grip the delaminated area and pull up. Then drilled a series of 1/4 inch holes with a Forstner bit, and cut the tip of the nozzle so it just fit in the holes.

In investigating the crack discovered something I've not seen mentioned before - there is plywood under the top layer of fiberglass. Did not know that. We decided that instead of a fiberglass repair, we would use plate washers, screws, and the adhesive to effect a repair. Predrilled a series of holes, and dry fitted the screws along the crack after stop drilling the end of the crack. This worked like a charm - the sides of the crack pulled down tight and the gap was closed. Pulled the screws, lifted on the edges of the crack, and were able to squeeze in a fair bit of adhesive. Refitted the screws and tightened down, which squeezed out the excess adhesive which was trowelled over the seam of the crack and the screws.

Moving onto the patch, we pulled up on the roof, fitted the nozzle tip into a hole, squeezed in a couple of shots of adhesive, and continued on until all the holes were treated. Then laid down some plastic wrap material, some 2X6s were laid over the rows of holes, and two bags of sand were placed over top. The adhesive could not squeeze back out of the holes, so it spread out under the patch from the weight of the sandbags.

I used the standard 5200, with a 7 day cure time. This morning, being day 7, I went back up and had a look. The sandbags, lumber and plastic were removed.

The delam is fixed - rock solid now. The crack is a done deal, glued down and sealed. End of story. Some very minor sanding over where the holes were and once painted, you wouldn't know we were there.

It's not the prettiest job, but it's fixed for good and didn't cost an arm and a  leg. I'll post a pic when I've cleaned it up.

Steve
1991 U225 Grand Villa