I am new to the forum and have been reading and have found out a ton of information.
Started with tent camping, then came the first pop-up (Jayco). Just rebuilt the entire top of the Jayco (finished that about a month ago) when my son who helped me called "with the deal of a life-time" as he put it. His friend bought a 94 Towlite 18 TL that needed minor repair and did not want to do the repairs (he is not handy at things like this) and would trade me my pop-up for the towlite. Made the trade...had been wanting a hi-lo anyway.
Now the real story begins. The minor repair has now grown to a total rebuild of the entire top half. The inside was/is in very good shape, as close to new as new goes. Other than curtains need to be replaced everything else was extremely well cared for. Outside is all aluminum, 1" metal rood framing, 1 by 4 wood wall supports. How I know this? Roof, both sides and back completely rotted.
This is what it suppose to look like...
Close ups of ceiling before replacement
Only side rail on door side, and both end rails were good, rest were rusted through and broken. Most of the insulation board was molded so all was removed. Got new 14 gauge metal tubing and hubby cut and welded new frames to insert. Spray painted and covered with duct tape as suggested by the kind guy at J & R. I gave hubby detailed drawing and specs for two frames which fit in and then were screwed to the good side rail and supported under by two by fours until we could get the long side rail attached, then screw all together. Replaced insulation board with fan fold foam insulation glued to metal roof.
Here is the new ceiling before added cross supports were screwed in.
After looking at what we had done decided that we should add 4 3/4" metal tubing as support from the ceiling framing to the bottom rail on both sides as close to the pulley systems as possible without interfering with the widows. While my son figured all of that out I got busy on cutting 2 x4's which I had all ready painted with several coats of exterior paint and getting them back in the tin casing they originally were in, attached new glide blocks were needed and attached new seal around bottom rail. By then my son had metal side supports cut and welded ready to be inserted. Metal was also cut and welded to wrap completely around the side rails where the cables attach, which we cut a channel on all 4 sides so the straping was flush with the 2x4.
Now comes cutting and fitting in all the 1 by 4 that have been pre painted to insert in the walls and tie everything together. At this point we were finally able to lower the top so that the framing would be easier. Needless to say I have ordered 5 30 foot rolls of butyl tape and have 4 tubes of Lexel Caulking on had. Lexel caulking was also used on seams before insulation was put in.
Going to sons tomorrow to do the work on framing, will keep posted if anyone likes.
Here are a few more pictures of the damage.....one is before we finished removing windows and siding.
Started with tent camping, then came the first pop-up (Jayco). Just rebuilt the entire top of the Jayco (finished that about a month ago) when my son who helped me called "with the deal of a life-time" as he put it. His friend bought a 94 Towlite 18 TL that needed minor repair and did not want to do the repairs (he is not handy at things like this) and would trade me my pop-up for the towlite. Made the trade...had been wanting a hi-lo anyway.
Now the real story begins. The minor repair has now grown to a total rebuild of the entire top half. The inside was/is in very good shape, as close to new as new goes. Other than curtains need to be replaced everything else was extremely well cared for. Outside is all aluminum, 1" metal rood framing, 1 by 4 wood wall supports. How I know this? Roof, both sides and back completely rotted.
This is what it suppose to look like...
Close ups of ceiling before replacement
Only side rail on door side, and both end rails were good, rest were rusted through and broken. Most of the insulation board was molded so all was removed. Got new 14 gauge metal tubing and hubby cut and welded new frames to insert. Spray painted and covered with duct tape as suggested by the kind guy at J & R. I gave hubby detailed drawing and specs for two frames which fit in and then were screwed to the good side rail and supported under by two by fours until we could get the long side rail attached, then screw all together. Replaced insulation board with fan fold foam insulation glued to metal roof.
Here is the new ceiling before added cross supports were screwed in.
After looking at what we had done decided that we should add 4 3/4" metal tubing as support from the ceiling framing to the bottom rail on both sides as close to the pulley systems as possible without interfering with the widows. While my son figured all of that out I got busy on cutting 2 x4's which I had all ready painted with several coats of exterior paint and getting them back in the tin casing they originally were in, attached new glide blocks were needed and attached new seal around bottom rail. By then my son had metal side supports cut and welded ready to be inserted. Metal was also cut and welded to wrap completely around the side rails where the cables attach, which we cut a channel on all 4 sides so the straping was flush with the 2x4.
Now comes cutting and fitting in all the 1 by 4 that have been pre painted to insert in the walls and tie everything together. At this point we were finally able to lower the top so that the framing would be easier. Needless to say I have ordered 5 30 foot rolls of butyl tape and have 4 tubes of Lexel Caulking on had. Lexel caulking was also used on seams before insulation was put in.
Going to sons tomorrow to do the work on framing, will keep posted if anyone likes.
Here are a few more pictures of the damage.....one is before we finished removing windows and siding.
Husband looks under and finds that the pan plug is falling out...opps there it goes and all the fluid is now poring out. Thank goodness husband is a diesel mechanic so not a problem....except of course we are in the middle of no where in an area that closes up at 5 pm, so no chance of getting it fixed that night. 
