Coleman Pop-Up Camper Roof: Size And Space Considerations

Coleman pop-up camper roofs are made of ABS plastic. In the mid-90s, Coleman introduced a one-piece, plastic roof on some of their higher-end pop-up trailers. The idea was good – no seams for water to leak in – but in reality, the ABS roof didn’t hold up on most trailers. The sun dried them out, and there was some severe cracking and delamination on many campers.

Coleman pop-up camper roofs come in different sizes depending on the model. For example, the roof of a Coleman Santa Fe is 6.5' x 8', while the roof of a Coleman Utah is larger.

Repairing a Coleman ABS roof

Coleman's ABS roof was a fantastic idea in theory: a one-piece roof with no seams for water to leak through. However, in reality, the sun dried out the plastic, and many campers experienced severe cracking and delamination. While Coleman did replace quite a few roofs, the pop-up camper division of Coleman/Fleetwood eventually went out of business, and now it is impossible to have your roof replaced.

But don't despair! Repairing your Coleman ABS roof is possible, and this article will walk you through the process step-by-step.

Step 1: Prepare the Roof

Before you begin repairing your Coleman ABS roof, it is important to prepare the surface. This includes cleaning the roof to remove any dirt, sap, or mould that may be present. You should also address any sagging or delamination issues before proceeding with the repair.

Step 2: Drill and Clean Out the Cracks

Once the roof is prepared, you can begin repairing the cracks. Start by drilling a small hole at each end of the crack to help prevent it from spreading further. Then, use a cutting wheel to clean out the crack and create a nice, clean surface for the patch to adhere to.

Step 3: Create the ABS/MEK Mixture

To create the patch for your cracks, you will need to mix equal parts MEK (Methyl Ethyl Ketone) and white ABS plastic pellets. MEK is a solvent that breaks down plastic, so be sure to wear gloves and a respirator when handling it. You can find ABS pellets on eBay, or use white airsoft BBs, which are made of ABS plastic. Mix the MEK and ABS pellets in a glass jar with a lid and let it sit for about 24 hours until the MEK has melted the plastic into a liquid patch.

Step 4: Patch the Cracks

Wipe down the cracks with a bit of MEK on a clean rag to create a nice surface for your patch to adhere to. Then, use a Popsicle stick or paint stirrer to apply the ABS/MEK mixture to the cracks. Allow the patches to dry completely before moving on to the next step.

Step 5: Sand the Roof

Once all the cracks have been patched, it's time to sand the entire roof. Use steel wool pads or fine-grit sandpaper to sand down the roof until it has a dull finish. This will create a clean surface for the bedliner paint to adhere to. Be sure to sand evenly across the entire surface.

Step 6: Tape Off the Camper

Use drop cloths and painter's tape to protect the areas of the camper that you don't want to paint. Be sure to tape off the roof edges and any other areas that you don't want to get bedliner on.

Step 7: Wipe Down the Roof with MEK

Don your respirator again and break out the MEK. Wipe down the entire roof with MEK, using clean rags or old t-shirts. This will create a nice, shiny surface for the bedliner to adhere to. Be sure to wear gloves to protect your hands from the MEK.

Step 8: Apply the Bedliner

Now it's time to apply the bedliner! We recommend using a product called Grizzly Grip, which can be purchased online. Apply a light first coat with a foam roller, wait 2-4 hours, and then apply a heavier top coat. Be sure to wear gloves and a respirator during this step and avoid getting the bedliner on your skin. Allow the bedliner to cure for at least 24 hours before using the camper.

Step 9: Replace the Roof Seal

Once the bedliner has cured, you may need to replace the roof seal, as it tends to shrink over time. You can purchase a new seal from colemanpopupparts.com. Wipe down the lip of the roof with acetone to ensure a clean surface for the new seal to adhere to. The new seal will have a tape adhesive on one side; simply peel off the backing and tap the seal into place with a rubber mallet.

Coleman roof structure

Coleman pop-up camper roofs are made of a variety of materials, including aluminium, ABS plastic, and fibreglass. The roof structure is composed of an outer skin of aluminium, 3/4 inch of foam, and 1/8 inch of luan, all glued together. The roof is supported by braces and a frame, which holds the luan/styrofoam/skin in place.

Coleman pop-up camper roofs can be prone to cracking and delamination, especially in ABS plastic roofs. Repairs can be made to Coleman pop-up camper roofs using a variety of methods, including patching with ABS/MEK goo and coating with a bedliner such as Grizzly Grip. It is important to address any delamination and to drill small holes at the ends of cracks to prevent further spreading.

Coleman pop-up camper roofs can also be replaced entirely if the damage is severe. This involves removing the outer shell and applying a new coating, such as fibreglass or bedliner, directly to the foam roof. It is important to ensure that the roof structure is properly braced and sealed to prevent water leakage.

Replacing a Coleman popup roof

Replacing a Coleman Pop-Up Roof

The Coleman pop-up camper roof is made of ABS plastic. Over time, the roof may develop cracks and leaks, which can be repaired or the roof can be replaced entirely. Here is a step-by-step guide to replacing a Coleman pop-up camper roof:

Step 1: Assess the Damage

Begin by inspecting the roof for any signs of damage, such as cracks, leaks, or delamination. Minor cracks can be repaired, but if the damage is extensive, a full roof replacement may be necessary.

Step 2: Gather the Necessary Materials and Tools

Before beginning the replacement process, ensure you have all the required materials and tools. This includes the new roof, work gloves, respirator, sandpaper or steel wool, rags, a cutting wheel, a drill, a rubber mallet, and any other relevant tools.

Step 3: Remove the Old Roof

Carefully remove the old roof from the camper. This may involve cutting or peeling away the existing roof material. Be cautious when handling the old roof, as it may contain toxic materials.

Step 4: Prepare the Surface

Once the old roof is removed, prepare the surface by cleaning and sanding the area. Use sandpaper or steel wool to roughen the surface, creating a better base for the new roof to adhere to. Ensure the surface is free of any dirt, debris, or residue.

Step 5: Install the New Roof

With the surface adequately prepared, it's time to install the new roof. Carefully position the new roof, ensuring it is properly aligned and secured in place. Follow the manufacturer's instructions for the specific type of roof you are installing.

Step 6: Seal the Edges

After the new roof is in place, focus on sealing the edges to prevent leaks. Use a suitable sealant or adhesive to create a watertight barrier along the edges of the roof. This will help ensure that your new roof is protected from the elements.

Step 7: Allow for Drying and Curing

Once the new roof is installed and sealed, allow adequate time for the adhesives and sealants to dry and cure. Refer to the manufacturer's instructions for specific drying and curing times.

Step 8: Test and Inspect the New Roof

After the roof has cured, test it by setting up the camper and inspecting for any signs of leaks or damage. Ensure that the roof is securely attached and that all seals are intact.

Step 9: Maintenance and Care

To extend the lifespan of your new roof, perform regular maintenance and care. This includes cleaning the roof, inspecting for any signs of damage, and addressing any issues promptly. Proper maintenance will help ensure the longevity of your replacement roof.

Roof seal leaks when closed

Coleman pop-up camper roofs are made of ABS plastic. The sun can dry out this material, leading to severe cracking and delamination. If you notice any leaks, you should repair your roof as soon as possible to prevent further damage.

Repairing a Leaky Roof Seal

• Identify the source of the leak. Check the roof for any cracks or gaps where water could be entering the camper.
• Clean the area around the leak with a mild detergent and water. This will remove any dirt, grease, or debris that could interfere with the repair.
• If the leak is coming from a crack in the roof, drill a small hole at each end of the crack to prevent it from spreading further.
• Use a cutting wheel to clean out the crack and create a smooth surface for the patch to adhere to.
• Mix equal parts MEK (Methyl Ethyl Ketone) and white ABS plastic pellets in a glass jar with a lid. This will create a liquid patch for the cracks.
• Wipe down the cracks with MEK on a clean rag to create a smooth surface for the patch to adhere to.
• Use a Popsicle stick or paint stirrer to apply the MEK/ABS mixture to the cracks. Allow the patch to dry completely.
• Sand the patched area with fine-grit sandpaper or steel wool to smooth out any rough spots.
• Apply a coat of UV-protectant bedliner to the roof to protect it from further damage and prevent leaks.
• If the leak is due to a damaged roof seal, remove the old seal and clean the area with acetone.
• Install a new roof seal, ensuring that the adhesive side is facing outwards. Use a rubber mallet to gently tap the seal into place.
• Crank the roof down to keep the seal in place while the adhesive cures.

Roof/floor repair and maintenance

The roof of a Coleman pop-up camper is made of ABS plastic. Over time, the sun dries out the plastic, leading to severe cracking and delamination. To repair the roof, you will need to drill small holes at each end of the crack to prevent it from spreading. Then, use a cutting wheel to clean out the crack and wipe it down with Methyl Ethyl Ketone (MEK) to give a nice surface for the patch to adhere to. Next, mix equal parts of MEK and white ABS plastic pellets in a glass jar with a lid and leave it for about 24 hours to create a liquid patch for the cracks. After that, use a Popsicle stick or paint stirrer to patch the cracks and let them dry. Finally, sand the roof down with fine grit sandpaper or steel wool to ensure a clean surface for the bedliner paint to adhere to.

For floor repair and maintenance, it is recommended to remove the old flooring and lay new vinyl plank flooring. The process involves gutting the camper, removing the cabinets, and pulling up the old linoleum. Then, prime the walls and give them a coat of paint. After that, snap together the vinyl plank flooring, staggering them for additional strength and visual interest. It is important to note that the flooring may not fit under the metal threshold at the door, so it may be necessary to bend the threshold out a bit and tap it on with a rubber mallet.

Frequently asked questions