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Cracks in Roof

Yahoo Message Number: 6497
Has anyone had experience with cracks appearing where the roof meets the front cap? CC has admitted that they ground the fiberglass too thin but will not pay to have it fixed. I have had 3 trys but nothing works for any period of time before the cracks reappear and I pay for the attempts. Any help would be greatly appreciated.

Rich Jacksic 1998 intrigue 10487

Re: Cracks in Roof

Reply #1 –
Yahoo Message Number: 6498
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Rich:

This may sound like a strange suggestion.
I would not think motor home dealers are likely to be highly qualified at critcal structural fiberglass repair. I am sure there are some exceptions.

I suggest you visit some boat places. Ones that profess to repair hull damage. A body shop that repairs damage on Corvetes is another source.
James M. Green Intrigue 110211

Re: Cracks in Roof

Reply #2 –
Yahoo Message Number: 6501
Jack, I too had the problem of a cracked roof. I called the factory, and they knew about the problem. They suggested I take it to a body shop. I suggested CC fix it. They said I couldn't get a service date for 6 weeks. I said no problem, I'll be there. When the service writer showed up, I told him I expected a break on the charges. He said he'd see what he could do, and would call me before they started work, and inform me how much it would be. He call a couple of hours later, and said 800 bucks and no break. It had to be fixed as the crack was all the way through, so I said go ahead, and figured I would fight it out when they were done. They fixed it that day, did a beautiful job, and informed me the bill would be 250. I paid it and thanked them, telling them I could live with that. As you are finding out, in is not an easy fix.

Good luck,
Avery Sloper

2000 32' Allure non-slide #30487

Re: Cracks in Roof

Reply #3 –
Yahoo Message Number: 6502
Hi Rich,

There are at least five major uses of fiberglass composite materials with many varieties of each - aircraft, vehicle (car and motorhome), surf boards, and boats. There is also lots of different epoxy resins for use with each type of composite mat. I have used composite materials for surf board repair and aircraft in manufacturer of experimental airplanes, the latter having the strongest characteristics.

Our motorhome has several hairline cracks by the windshield and rear roof cap where it connects to the side. I have sprayed Krylon into them as a temporary stopgap. When the separation expands beyond hairline then major repair will be done. First, asking CCI who is the mat manufacturer, type, weight, weave pattern (bi-directional but does the weave vary) and the resin and hardener used. Then there is the issue of purchasing the duplicate protective coating (color) and clear coat. If I weren't doing the work myself, with the proper matierials in hand, I would approach (in the order of expertise) small surf board builders, experimental aircraft builders at small airports, composite boat builders, auto repair shops and finally motorhome maintenance/repair shops. CCI at Juncion City would surely do a good job.

Depending how much fiberglass separation has occurred under the protective coating determines how much mat is removed and replaced with layers of new mat which are arranged at bias angles for increased strength - usually 2 - 4 layers. Sanding, filling and resanding many times are required to get the original flat or curved feathered finish. Filling can be done with resin or other materials made specifically for filling. Painting is another effort requiring a base coat to provide uv protection, color coat and clear coat all in mulitcoat layered fashion with several passes for each layer. This requires craftmanship and performed over several days.
Fred Kovol

Re: Cracks in Roof

Reply #4 –
Yahoo Message Number: 6504
Thanks for the reply Fred, I did all of the things you suggested, i spoke with Jim Cooley to determine the original mat makeup, he said they used the roughest nondirectional weave, in other words the cheaper, we tried 3 different mats and resins on the 3 different repairs and all have eventually cracked through, we built up 4 layers to add strength but no help. I'm thinking of tring to remove the cabinets from insideor the help. and attacking it from there. Anyone have experience in removing them? Thanks for the help. I got help from experienced fiberglass people who work on race car bodies which are prone to cracking because of extreme vibration.
Rich Jacksic #10487 Intrigue

Re: Cracks in Roof

Reply #5 –
Yahoo Message Number: 6506
Hi Rich,

I have another concern - the roof floats. Mine is rippled probably from quatering high winds. As that roof flexes and you say it is the cheapest mat - doesn't sound good. I would still find the manufacturer and contact them as to the weight, weave, etc. Certainly, layering up on the inside would help reduce the vibration. Applying rib stiffeners made of layered fiberglass (exterior in your situation) is used in the experimental airpane manufacturer of the cowl area to remove vibration. It is probably the better approach.
Fred Kovol
 

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Reply #7 –
Yahoo Message Number: 6505
We need to know the name of the product that was talked about sometime back on refinishing the coach armour....some product that removed the scratches and made it clear again...thanks if you all remember..

Huie and Mary Lindsey
Intrique 10379 - '97