DIY Roof Renovation

Topic: DIY Roof Renovation (Read 1646 times) previous topic - next topic

DIY Roof Renovation

September 01, 2011, 09:33:51 am

Greetings,

Doing a DIY roof renovation right now on my 91 U225. There was a previously installed patch that needed attention, along with a crack from corner of said patch. The Kool Matic vent cover has been refurbished, the fridge vent rescreened, the antenna removed and holes patched, and the entire roof has been sanded with 100 grit yesterday in preparation for two coats of an EPDM roof coating. Once washed and all seams sealed with the supplied tape, the coating goes on, and it is guaranteed for 10 years against leaks and should last 20 years with nothing more than an occasional wash. (At least that's what they say). Link --> RV ROOF REPAIR

The coating is 92% reflective, so should provide a measure of heat gain reduction inside. I recently took a series of temp readings so I could compare before and after. The best part will be - no more chalking.

Total cost - around $450, with all materials, including fixing the delaminating roof patch.

Gotta go get a bucket and cleanser and get up there with a deck brush to scrub her down... will post pics when it's all done.

Steve

Re: DIY Roof Renovation

Reply #1 – September 01, 2011, 10:17:43 am

Steve, When you get done you are more than welcome to come over to my house and show me by example how to do this. I will watch closely while you do it and I'll supply the liquid refreshments.

I never cease to amazed at the depth of talent on this forum. I'll bet that this bunch could show NASA a thing or two... ( and at lower cost ).

Gary B

Re: DIY Roof Renovation

Reply #2 – September 01, 2011, 09:36:48 pm

Hi Gary,

I dunno - I read Tom Sawyer once. Remember something about whitewashing a fence...

There are a great many very knowledgable and sharp people here indeed. I am often amazed at the depth and breadth of the technical knowledge I encounter. I guess Foretravel owners know their stuff - which is why they bought one.

I've gotten many ideas and time saving info from the fine folks here.

Almost done with this roof. Been a lot of work and time. Lost count of how many times I've been up and down a ladder since I began.

Today the roof and gutters were scrubbed clean, and the seam tape applied. I thought applying the tape would be a snap. Ended up taking three hours, and a great many curses were uttered during the process. This tape is the stickiest stuff I've ever used. The hardest part is getting the backing paper to start peeling away without stretching the corners. And once it's touched something, that's it. You only get one shot at it. It won't come off without destroying it, as advertised. So while I did less than stellar job with the tape, the seams are sealed well, and no one looks up there anyway.

Tomorrow morning, once the dew has cleared the coating goes on. By Saturday morning, it will be fully cured and I'll be able to replace the covers and finally install the new front A/C next week.

Something I've learned - you don't realize just how big the coach is until you have to sand the roof.

Steve

Re: DIY Roof Renovation

Reply #3 – September 05, 2011, 05:16:45 am

It's finally done. Finished last night at dusk. Just in time for 5 days of rain.

The weather has been an issue. Temps and humidity have been such that there is dew on everything in the morning. Had to wait for that to dry before I could do anything. And as more of the coating was added to the roof, the dew took longer and longer to dry. Yesterday it took until 1pm.

It didn't take long to figure out why. The coated areas were at least 10 degrees cooler than the rest of the coach. So even when the temps were above the dew point, the roof was cool enough that condensate formed. And as most of the sun's heat is reflected, it took quite some time to dry.

Yesterday evening I went up to put the covers back on. It wasn't hot; the sun was already dropping behind the trees. Yet by the time I was done, I was completely soaked in sweat. Why? The coating reflected my body heat back at me.

I found that most of the screws securing the roof side rails were somewhat loose. Not a surprise after 20 years of heating/cooling and road travel. Snugged them all up, and decided to extend the coating down to the gutters, to make sure the rails and screws were sealed.

By the mfrs coverage data I calculated I'd have just enough to do the recommended two coats with the 5 gallons purchased. Used a brush to cut in and a deep pile roller with a 3/4 inch nap as suggested, and applied it very liberally as instructed. However, after two coats I still had a 1/2 pail left. So, I kept going until it was about gone - 4 coats were applied in the end, each coat perpindicular to the other. Going lengthwise, I had to climb up on the roof, but going across I was able to do it from a ladder with an extension handle. The roller gave it a nice texture.

All told, about 40 hours went into this roof renovation, including the time spent refurbishing the vent fan cover assembly. And it was worth it. I've not taken any temp readings yet for comparison purposes, but the coach was 5 degrees cooler inside than outside yesterday afternoon (and the awnings were all up).

I've attached some photos I took last night. The quality isn't that good, but it was already getting dark when I snapped them. I'll get some more when the rain stops. That rear A/C cover didn't look bad when I took it off, but it sure looks grungy now.

Steve

Re: DIY Roof Renovation

Reply #4 – September 05, 2011, 08:21:27 am

Grabbed a few pics from below just now.

The coach was painted a few years ago by the previous owner, and the sides are a creamy ivory color. There was some concern on my part with regards as to how the white coating would look with the ivory. Was hoping not to look like a school bus, but sealing everything properly took priority over cosmetics. There is a contrast there, but it isn't bad at all in my eyes.

Steve

Re: DIY Roof Renovation

Reply #5 – September 05, 2011, 08:25:31 am

Steve, I think the whole coach looks great.
Gary B

Re: DIY Roof Renovation

Reply #6 – September 05, 2011, 08:39:38 am

Thanks Gary.

She's showing her age (as I am), but I think there's a lot of life left in her.

Steve

Re: DIY Roof Renovation

Reply #7 – September 05, 2011, 08:49:14 am

Steve, The way these FT's are built I think you could keep one running forever. Mine is a 95 and I will bet that it will still be on the road when SOB's are in the scrap yard.
Gary B

Re: DIY Roof Renovation

Reply #8 – September 05, 2011, 12:25:46 pm

Steve, I think your coach is good for another 20 years. You certainly do good work and take pride in ownership.

Re: DIY Roof Renovation

Reply #9 – September 05, 2011, 12:56:24 pm

Looks beautiful! Anything that makes it easier to keep cool is a plus as well. Let us know how she does next time you get in hot conditions...
Don

Quote from: Merle Hench – September 05, 2011, 08:21:27 am

Grabbed a few pics from below just now.

The coach was painted a few years ago by the previous owner, and the sides are a creamy ivory color. There was some concern on my part with regards as to how the white coating would look with the ivory. Was hoping not to look like a school bus, but sealing everything properly took priority over cosmetics. There is a contrast there, but it isn't bad at all in my eyes.

Steve

Re: DIY Roof Renovation

Reply #10 – September 06, 2011, 05:31:15 am

Thanks for the kind words folks.

It's been somewhat of an ordeal, trying to finish before the remnants of Lee arrived. Current forecast calls for rain through Saturday. So let's see - in the last two weeks - an earthquake, a hurricane, and now a tropical storm, or whatever they are calling it. Yikes.

I sure do appreciate how well these machines are made. I fully understand why many people say they'd rather have an older Foretravel than a newer anything else. This one's a keeper for me. Just need to take good care of her. Soon enough she will be my only home. Looking forward to becoming a gypsy.

Steve

Re: DIY Roof Renovation

Reply #11 – September 06, 2011, 09:42:47 am

I am glad you made it! Sounds like your timing was perfect. We too are looking forward to leaving the sticks and bricks to try out the gypsy lifestyle. I think we will have the right machines for it (future tense for us since we are still waiting...).
Don

Quote from: Merle Hench – September 06, 2011, 05:31:15 am

Thanks for the kind words folks.

It's been somewhat of an ordeal, trying to finish before the remnants of Lee arrived. Current forecast calls for rain through Saturday. So let's see - in the last two weeks - an earthquake, a hurricane, and now a tropical storm, or whatever they are calling it. Yikes.

I sure do appreciate how well these machines are made. I fully understand why many people say they'd rather have an older Foretravel than a newer anything else. This one's a keeper for me. Just need to take good care of her. Soon enough she will be my only home. Looking forward to becoming a gypsy.

Steve

Re: DIY Roof Renovation

Reply #12 – September 08, 2011, 05:24:40 am

I agree. When I began going through this machine I expected to find corners cut and details overlooked. I was very pleased to see that not only where all the details taken care of, they went beyond what I would have done.

Still waiting for the rain to end. After 4 days one gets weary. Wish we could send that to Texas.

Supposed to be warming up again going into next week, so I can hopefully take some temp readings to get a sense of how effective this coating is at keeping the heat out. From an August 20th post in another thread about improving energy efficiency, I collected the following numbers prior to beginning the renovation. Note the roof temps were higher than the asphalt (!)

Quote from: Merle Hench – August 20, 2011, 03:31:25 pm

Greetings,

For giggles, today I took my infrared thermometer and took some temperature readings outside and inside the coach. Some of the numbers surprised me (all numbers in Fahrenheit degrees).

Ambient - 84.5, 69% humidity (yuck), UV index - very high
Asphalt driveway - 135.6

The coach was closed up due to thunderstorms last night, although both vents were open. My makeshift Reflectix windshield cover was in place, and all the awnings were up when I came out at 1:30 pm. The afternoon sun hits the front driver's side late morning, then slides across to cover all the driver's side and roof. The passenger side never gets direct sun.

Outside of single pane windows - 108 to 110 in the sun, ambient in the shade
Outside of coach - in the sun - ivory color - 107 to 112, dark gold color - 122 to 130.
Inside temps - 86.6 - I was surprised, given the awnings were up. That windshield cover really makes a major difference. And this was with the windows all closed.
Kitchen vent opening (inside cover is off at the moment) - 106
Bathroom vent opening (1/2 open) - 105
Inside of skylight - 130!!! I knew it got hot, but this is ridiculous. Going to cover that with some Home Depot bubble and figure something out. I like the light and the headroom, but the heat loss and gain is nuts.
Ceiling temps - front cap - 86.4, main coach - 92.4, rear cap 85.1 - I find this interesting, as the caps don't really have any insulation in them.

Lastly, I climbed up to get roof temps. The roof is dirty, and there is no gelcoat left to speak of. Temps ranged from 130 to 140. Higher than I expected. Hotter in spots than the black asphalt driveway. Interesting.

Yesterday I ordered seam tape and an EPDM coating for the roof. The coating has a reflectivity of 92%, so will see just how much cooler the roof and inside turn out to be after I'm done applying it (this week, schedule and weather permitting).

Spent a lot of time researching roof coatings and calling manufacturers. In the end, I chose Polycoatings RV Roof EPDM reflective coating --> RV Roof Repair Motorhome Roof Coating | Palycoatings International . A maintenance free roof (aside from cleaning) for 20 years appeals to me. . I'll let ya know how it turns out.

Steve

Re: DIY Roof Renovation

Reply #13 – September 08, 2011, 10:02:43 am

Steve, for what it is worth, make sure the four screws holding your rear air conditioner cover in place are sealed. I had to track down a leak inside the coach. Turns out the driver's side rear screw let water in, it ran thru the insulation, down some sheetmetal, then along the wiring until it leaked thru onto the carpet.

At the time I didn't have any RV caulk so I used Shoe Goo on the bolt heads until the depressions were filled. Still not leaking and almost a year has gone by!

Re: DIY Roof Renovation

Reply #14 – September 09, 2011, 09:38:55 am

Thanks Nitehawk.

I'm thinking some neoprene fender washers under the supplied stainless washers would work (?). Am reluctant to seal the screws in, as the cover does need to be pulled fairly regularly to clean the A/C unit. I'll give it a try and see what happens.

Steve

Re: DIY Roof Renovation

Reply #15 – September 14, 2011, 06:20:30 am

Had to wait for Lee to finish dumping water on us, but the roof is finally completed. Yesterday the new front A/C unit was installed, as well as a new (free) bathroom fan vent cover from Fantastic Fan. Coach is parked under a cherry tree, and the leaves have already left the roof looking dirty, but here's a couple of pics of the finished job. Still need to clean off a couple of spots where I got coating on the roof rails, but otherwise job done.

Did note that some of the A/C cover screws left a little of the slot exposed, so added neoprene fender washers under the stainless washers. Done deal. Onwards to the gen bay resto and slideout mod...

Steve

Re: DIY Roof Renovation

Reply #16 – September 14, 2011, 06:30:37 am

Forgot to mention - took some temp readings with the IR thermometer. It wasn't quite as warm yesterday as when the original numbers were taken, so it's somewhat of an apples and oranges comparison. Also the windows had been open and the awnings were down.

Ambient temps were 81 degrees, with 69% humidity. The coach body measured at 107 (ivory) and 120 (dark gold). The driveway came in at 110 degrees. The roof itself - a most interesting thing - the number came in at 104 degrees, but if you put your hand on the roof it felt cool to the touch. I guess the IR thermometer was seeing the IR reflecting off the roof, as opposed to what the roof temp actually was. Hoping to see a day where I can do a more direct comparison of the numbers, but seems we're heading towards cooler temps from here on out.

I haven't lived with this for any length of time, but the roof is now sealed, there'll be no more chalking, and other than washing occasionally requires no maintenance for the next 20 years. Keeping the coach cooler in the hotter months is a bonus. This was a project well worth the investment in time and money.

Steve

Re: DIY Roof Renovation

Reply #17 – October 07, 2013, 01:15:06 pm

Steve,
I need to do this on to my FT, sooner than later. This past weekend we had rain and i discovered a small leak over the head of the bed. I think maybe it was the clearance lights ( I took them all out cleaned and reinstalled with generous amount of silicon seal on Sunday afternoon). Now the back trim that connect the roof to the back (has lots of screws) also does not look 100% to me. So it is possible that maybe the leak is coming from there. On your pictures I noticed that that's where you stooped your roof seal. Your trim is painted. Since you have first hand experience I wanted to ask you; if I cover that trim with the (Tape-Kote 4" RV Roof Seal Tape) before I apply the seal over it do you think it will be ok?
Essentially that tape is made to go over screws, joints, trims no?

Thank you for your help,
AL

Re: DIY Roof Renovation

Reply #18 – October 07, 2013, 02:59:26 pm

Shoe Goo...such wonderful stuff. I got tired of the baby moons coming off the front wheels so I bought the third set and used Shoe goo. Mechanic at lubrication time said he had no idea how to remove them. Said he'd never seen them fastened that tight. If Gorilla Glue won't do it then Shoe goo will. Even better than...wait for it...Duct Tape!

Re: DIY Roof Renovation

Reply #19 – October 07, 2013, 06:06:40 pm

While I would like to prevent chalk residue staining the sides of my basically 'white' 2001 gel coated roof(not newer dark colors), I do want to be cautious as to how I address any added input on it so continue to apprecaite discussions on this subject.

.. A thin layer of paint(easily sanded off.. or tweaked if necessary) as FT and Extreme approach the subject?...or with 5 gallons of rubbery material?
No offense ever intended but if I had an 80, 90 vintage, or a later 2000 vintage coach.. my approach with materials might be different.
Cost of materials might not be very different, but maybe the issues are.....(?)......and so the materials used might play more importantly. yeah/neah?

Re: DIY Roof Renovation

Reply #20 – October 07, 2013, 06:16:58 pm

Quote from: MemoryRoads – October 07, 2013, 06:06:40 pm

While I would like to prevent chalk residue staining the sides of my basically 'white' 2001 gel coated roof(not newer dark colors), I do want to be cautious as to how I address any added input on it so continue to apprecaite discussions on this subject.

.. A thin layer of paint(easily sanded off.. or tweaked if necessary) as FT and Extreme approach the subject?...or with 5 gallons of rubbery material?
No offense ever intended but if I had an 80, 90 vintage, or a later 2000 vintage coach.. my approach with materials might be different.
Cost of materials might not be very different, but maybe the issues are.....(?)......and so the materials used might play more importantly. yeah/neah?

So are you saying you would not use ( RV ROOF REPAIR ) ?
I am still on fence to take it to NAC (FOT or Extreme ) but I really like what the polycoating do with Sun & Heat. Also possibility of saving $1000 by doing it myself. Please say more ....

Re: DIY Roof Renovation

Reply #21 – October 07, 2013, 06:17:45 pm

Xtreme Paints and adds some "grit", FT uses a material that is a white bed liner, looks exactly like FRP when complete.I have Xtreme, but it seems both FT and Xtreme customers happy so far.

If you want a conclusive answer, wait ten years and we can report how it held up! :-)

For now, you pay your money and make your choice. For me, I don't think there is a bad choice, but I love Xtreme's workmanship

Re: DIY Roof Renovation

Reply #22 – October 07, 2013, 06:23:11 pm

Thank you Tim. I did go back and read all the extensive postings about the FT vs Xtreme about this; If I do decide to go this route, it is a difficult choice but with so many happy customers it looks like I can't lose with any one.

Re: DIY Roof Renovation

Reply #23 – October 07, 2013, 06:42:03 pm

Al, 'propman'... I am saying that there are things to be considered if you have a Million Dollar coach, or a $100,000. coach or a $10,000 dollar coach.
You...make your choices.

I re-foofed my '91 class C and will keep her for some time.

I love that baby!

I love my Foretravel 2001 too!, but might not...use similar materials on them. Why?

My 2nd home..the FT will get the best of the best... I expect to live in her for some time and travel our hemisphere.

My Class C is a wonderful coach, but it is.............what it is!!! a '1991' in incredible "Go there NOW" readiness, but...

"it is what it is" Class C's of this vintage has much less value.

Re: DIY Roof Renovation

Reply #24 – October 07, 2013, 06:49:30 pm

let me be more clear. Extreme and Foretravel do wonderful work and at very competitive pricing.

however, if YOU want to do your own work, you should always consider at least half the cost on the job. "U" are fee and materials you purchase can be had at much less than retail.'
Other than 'that', you will know what you have done immediately.

To some...that is not important and that is OK too, as the work is so often done with extreme care from the very few companies we consider.

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