Restoring A 2005 Starcraft: A Step-By-Step Guide

Starcraft has a rich manufacturing history dating back to 1903, initially producing farm equipment and later boats. In 1964, Starcraft entered the recreational vehicle (RV) market, starting with a folding camping trailer. Over time, Starcraft expanded its product line to include truck campers, fifth wheels, and travel trailers, catering to various mobile vacation needs. While Starcraft no longer produces truck campers after 2009, their legacy lives on through their existing models and those seeking to refurbish older ones, such as the 2005 Starcraft truck camper. Rebuilding a 2005 Starcraft truck camper can be a rewarding project for those with a passion for DIY and camping. It involves a range of tasks, from repairing water damage to replacing insulation and refurbishing the interior. With dedication and the right tools, a 2005 Starcraft truck camper can be transformed into a comfortable and functional mobile vacation home.

Removing the canvas

The first step in the roof rebuild is to remove the canvas of the pop-up camper. The canvas slides into a groove at the bottom of the plastic curtain tracks and is held in place by several screws. Remove these screws, then unzip the canvas at each corner. Gently pry the track up where the screws were to fully release the canvas from the track. Once this is done, slide the canvas away from the roof and set it aside.

With the canvas removed, the next step is to remove the curtain tracks. Label and set aside the tracks for future reference. Unplug the electrical wiring that runs up to the roof. To ensure safety and stability, prop the edge of the roof up on 2x4 lumber cut to the same length. This will prevent the roof from falling during the disassembly process.

Lowering the Roof

Once the canvas and curtain tracks are removed, it's time to lower the roof onto the 2x4s. Release the tension from the cables and unscrew the bolts attaching the lift arms to the roof. Carefully slide the lift arm off the bolt and set it aside. With the 2x4s supporting the roof, grab a partner (or two) and lift the roof up and off the body of the camper. Place the roof upright on the floor of the garage or workspace.

Taking the Roof Apart

Now it's time to disassemble the roof. Using a paint scraper, carefully remove the metal trim from around the outside of the roof. This can be challenging due to the layers of caulk and butyl tape that need to be dug through and scraped off. Acetone can be used to loosen the caulk, but be cautious to avoid damaging the thin aluminum skin of the roof. Once the top trim is removed, flip the roof over and sweep the floor to ensure no debris can cause dents or damage.

Next, remove the remaining trim, brackets, interior lighting, and vent garnish. Then, use a rubber mallet to gently tap and loosen the long side panels of the roof. Once the sides are removed, start pulling back the ceiling, which consists of wallpaper and thin luan paneling glued to insulation foam and a wooden frame. The paneling can be tricky to remove due to the strong glue, so use a router to create a channel in the paneling and insert a paint scraper to lift and remove pieces.

Removing the Insulation and Framework

The insulation foam is glued to the roof, so use a long-handled floor scraper to pull it up in large chunks. Wear a respirator and nitrile gloves for safety during this process. To remove the roof framework, use a combination of a crowbar and a rubber mallet. Soak the wood with acetone to help loosen the bond and make removal easier. This process is tedious and requires a lot of scraping and scrubbing. Remember to be gentle to avoid damaging the thin aluminum skin of the roof.

Lowering the roof

Step 1: Understanding the Roof Mechanism

Before attempting any adjustments, it is crucial to understand the roof mechanism of your Starcraft camper. Familiarize yourself with the crank handle, lift system, and roof mounting brackets. These components play a vital role in raising and lowering the roof.

Step 2: Gather the Necessary Tools and Parts

Ensure you have the required tools and parts for the job. This may include a crank handle, roof gauge cable, mounting brackets, and any other specific parts recommended by Starcraft or a qualified RV technician.

Step 3: Prepare the Camper

Park your camper on level ground and engage the parking brake. Ensure that the area above the camper is clear of any obstacles, and inform others nearby that you will be lowering the roof to avoid any accidents.

Step 4: Lowering the Roof

• Locate the crank handle and insert it into the appropriate socket on the lift system.
• Turn the crank handle in a clockwise direction to lower the roof. It is important to turn the handle slowly and smoothly to avoid any sudden movements that could cause damage or injury.
• As the roof lowers, pay attention to the roof mounting brackets and ensure they are securely attached.
• Continue cranking until the roof is fully lowered and secure.

Step 5: Securing the Roof

Once the roof is lowered, ensure that it is securely locked into place. Refer to your Starcraft manual or seek advice from a qualified technician if you are unsure about the securing process.

Step 6: Final Checks

After lowering the roof, conduct a thorough inspection to ensure that all components are functioning correctly. Check the seals, hinges, and moving parts for any signs of wear or damage. Regular maintenance and lubrication of these parts will help ensure smooth operation and prolong the life of your camper's roof mechanism.

Additional Considerations:

• When lowering the roof, always be mindful of your surroundings and maintain a safe distance from bystanders.
• If you encounter any resistance or unusual noises during the lowering process, stop and investigate the cause before proceeding.
• Consult a qualified RV technician or a Starcraft specialist if you have any doubts or concerns about the process.

By following these steps and taking the necessary precautions, you can safely and effectively lower the roof of your 2005 Starcraft truck camper.

Taking the roof apart

The first step in taking apart the roof of a pop-up camper is to remove the canvas. The canvas slides into a groove at the bottom of the plastic curtain tracks and is held in place by several screws. Once these screws are removed, the canvas can be unzipped at each corner and slid out of the track. It may be necessary to gently pry up the track where the screws were to release the canvas. With the canvas removed, the curtain tracks can also be taken off and set aside.

Next, the electrical wiring running up to the roof should be unplugged, and the edge of the roof should be propped up on 2x4 lumber to prevent it from falling during disassembly. The bolts attaching the lift arms to the roof can then be unscrewed, and the lift arms can be carefully slid off the bolts and set aside. With the lift arms removed, the roof can be lifted by each corner and placed upright on the floor.

At this point, the RV vent and all metal trim around the outside of the roof must be removed. This can be challenging due to the presence of multiple layers of caulk and butyl tape, which will need to be scraped off. Acetone can be used to loosen the caulk, but care must be taken not to damage the thin aluminium skin of the roof during this process. Once the top trim pieces are removed, the roof can be flipped over.

The next step is to remove the remaining trim, brackets, interior lighting, and vent garnish. The long side panels of the roof can then be gently tapped with a rubber mallet to separate them from the top. The ceiling, which consists of wallpaper with thin luan panelling glued to insulation foam and a wooden frame, can now be pulled back. The luan panelling may be tricky to remove due to the strong glue, and a router may be needed to create a channel for a paint scraper to get underneath.

After the ceiling is removed, the insulation foam can be scraped up using a long-handled floor scraper. This will help to avoid a sore back from bending over! Finally, the roof framework can be removed using a crowbar and rubber mallet. This process may require soaking the wood with acetone and working in small sections until all the pieces are removed. Remember to wear a respirator and nitrile gloves when working with acetone for safety.

Removing the frame

To remove the frame of a pop-up camper, you will need a crowbar, a rubber mallet, acetone, and nitrile gloves. It is also recommended to wear a respirator for safety. The process is tedious and involves a lot of scraping and prying. Here is a step-by-step guide:

• Remove the canvas by unscrewing and unzipping it from the plastic curtain tracks.
• Take out the curtain tracks and set them aside.
• Unplug the electrical wiring that runs up to the roof.
• Prop the edge of the roof up on 2x4 lumber to support it while you work.
• Lower the roof onto the 2x4s and release the tension from the cables.
• Unscrew the bolts attaching the lift arms to the roof and set the arms aside.
• With help, lift the roof off the body of the camper and place it upright on the floor.
• Remove the RV vent and metal trim from around the roof, using a paint scraper to dig through the layers of caulk and butyl tape. Be careful not to gouge the thin aluminum skin of the roof.
• Flip the roof over and remove the remaining trim, brackets, interior lighting, and vent garnish.
• Use a rubber mallet to gently tap and remove the long side panels of the roof.
• Pull back the ceiling, which may include wallpaper and thin luan paneling glued to insulation foam and a wooden frame. The paneling can be tricky to remove, so use a router to create a channel and then slide a paint scraper underneath.
• Scrape up all the insulation foam, which may be strongly glued. A long-handled floor scraper can be useful for this step.
• To remove the roof framework, use a combination of the crowbar and rubber mallet. Soak the wood with acetone to help loosen it. This step may require multiple applications of acetone and some elbow grease.
• Continue scraping, prying, and applying acetone until most of the wood and front and back-end pieces are removed.
• Once only the aluminum skin remains, gently clean the glue residue from the inside of the skin with Scotch Brite pads and acetone.

Cleaning the aluminium

Aluminium is a versatile, durable, corrosion-resistant metal that is used for a wide range of applications. It is important to clean aluminium to maintain its longevity. Here is a detailed guide on cleaning the aluminium parts of your 2005 Starcraft truck camper:

Step 1: Removing Dirt

First, remove any loose dirt or debris from the aluminium surface. You can use a regular washing detergent and water to clear the surface of any dirt. Rinse off the detergent and debris and inspect the surface for any remaining dirt. If necessary, repeat this step until the surface is clear.

Step 2: Applying a Cleaning Solution

To clean the aluminium thoroughly, you can use one of the following methods:

Vinegar Solution

Mix equal parts white vinegar and water to create an acidic solution. Dip a soft cloth into the mixture and scrub the aluminium surface. For more stubborn residue, boil the water before adding vinegar, then pour the hot solution over the area and let it sit for about 30 minutes before cleaning with a sponge or cloth.

Mild Detergent Solution

Mix a small amount of mild detergent, such as dish detergent, with warm water. Apply the solution to the aluminium using a non-abrasive sponge or soft cloth, as aluminium can scratch easily. Rinse the surface well with clean water. This method is suitable for cleaning large aluminium surfaces, such as furniture.

Borax Solution

Borax, found in the laundry aisle of supermarkets, can also be used to clean aluminium. Sprinkle it onto the surface and scrub with a damp sponge or cloth until the aluminium is shiny. Alternatively, mix borax with a small amount of water to form a light paste, then apply it to the problem area and scrub with an old toothbrush. Rinse the surface well and dry it to restore shine.

Cream of Tartar or Lemon Paste

Mix cream of tartar with water to form a paste, or simply use the juice from a lemon. Apply the paste or juice to the aluminium surface using a soft cloth, rubbing in circular motions. Use an old toothbrush to reach corners and other hard-to-clean areas. Rinse with clean water and dry the surface with a soft cloth. Repeat if necessary.

Step 3: Removing Oxidation

Aluminium can develop oxidation over time, appearing as a white or grey powdery residue. To remove oxidation, mix equal parts white vinegar or lemon juice with water. Soak a soft cloth in the solution and gently scrub the oxidized areas. Alternatively, rub a slice of lemon on the surface and then wipe it off with a wet cloth or paper towel.

Step 4: Polishing

To restore shine to your aluminium surfaces, you can use aluminium polish or a home remedy such as cream of tartar paste. Apply the polish or paste to a soft cloth and buff the surface using circular motions. Then, wipe away any remaining product with a clean, dry cloth. Note: Do not use aluminium polish on food utensils or anything used for food preparation, as it can be toxic if ingested.

General Tips:

• Always test your cleaning solution on a small, inconspicuous area before applying it to the entire surface.
• Avoid using abrasive materials like steel wool or abrasive pads, as they can scratch the aluminium.
• Regularly clean your aluminium surfaces to maintain their appearance and functionality.

Frequently asked questions