Overhead Cab Reconstruction

We are learning that Class C Motor homes are notorious for roof leaks! 

The only way to make this RV right is to strip it all the way down to its bones.

It took months for the RV dry out completely.

 

  We removed the water damaged wood and old Styrofoam insulation and waited. 

  

We added new 1 x 1 treated wood to the structure using the old wood as a guide.

  

  We glued the exterior skin to the interior structure and shored it up using two ladders (which are just out of range for this picture, but they are on the right) and 2 x 4s. 

 

Jeff then added new insulation -- Owens Corning R50 1 inch foam bought at Menards-- using a circular saw to make the cuts...

and glued it in with waterproof adhesive.

It was then finished with a 1/2 inch plywood as the new surface material.

For now this is as far as we can go.  The front window is out, the marker lights need to be replaced, and the roof needs to be sealed.  Until these three mini projects are complete, and we can be sure there are no leaks... this project is to-be-continued. Once all that is complete and Jeff can finish the interior of the bunk, the RV will start really looking like an RV again!!

More Wicked Water Damage

Is that a hole in your RV?

 

Yes, yes it is!

There was sooooo much water damage done to the bulkhead that it rotted the wood behind the driver's seat beyond repair! Mighty Jeff removed the damaged wood and outer skin of the RV in an effort to make a durable repair. 

This is the fix...we (I mean Jeff) cut sections of particle board using the outer skin as a template and glued it in place.  Those are the used, well-worn brake rotors from my Ford Expedition... they make great weights to hold the outer skin in place while the glue sets :)

We rolled up carpet to "seal" the hole while the glue dried to keep the honest animals out. I know... if they really wanted in, they would have easily found their way!  Maybe it just made us feel better?? I don't know.  But man, look at this picture... what a mess!! And, you'd think by now I would have taken down those hideous curtains??

When the "wall" was finished, Jeff secured it to the RV with screws.  Good as new... maybe even better??

Wicked Water Damage

Water on the inside is never a good thing. 
We knew going into this project that there would be surprises, but we never thought ...

The more we pulled up the laminate, the more water damage we found! UGH!! The only reason I'm sharing this - and it's not to complain -  is so others who intend on buying a Class C Motorhome will benefit from our experiences. The guy we bought it from is either super stupid, or dumb like a fox! I will tell you this... we will never make this mistake again.

We ended up tearing it all out. What a mess.  If you look closely, you can see the shine from the still wet plywood. I cried.

There will be no camping this year.