Adjusting Your Pop-Up Camper Roof: A Step-By-Step Guide

Pop-up camper roofs are a great way to create extra space, but they can be a little tricky to adjust. The process involves altering the pulley system that controls the height of the roof. This system usually includes a series of cables and pulleys that work together to raise and lower the roof. Adjustments are typically made by changing the position of the pulleys, which can impact the height of the roof by several inches. It's important to make these adjustments with the roof in the correct position, and to ensure that the camper is level. Before making any adjustments, it's also crucial to identify the source of the problem, which could be anything from a bent frame to water damage.

Adjusting the height of a pop-up camper roof

Firstly, it is important to identify the type of adjustment your camper roof requires. A common issue with pop-up camper roofs is an uneven height from front to back, which can cause the door to bind. To resolve this, you will need to adjust the pulley system that controls the roof height.

Before making any adjustments, ensure that your camper is level. You can then proceed to adjust the pulleys, which are located at the back of the trailer. Lower the roof so that it rests on the beds, creating slack in the cables. Under each corner of the roof, you will find a pulley with three holes. These holes allow you to adjust the roof height. Check if the holes are all in the same position, as someone may have adjusted only two of them.

To make the necessary adjustments, remove the clip and push-up pin from the pulley. Adjust the position of the pin to the desired hole and reinstall it by pushing it back in and securing it with the clip. Repeat this process for each pulley, focusing on the sagging end of the roof. Each hole adjustment will change the roof height by approximately 1 1/2 inches.

After making the adjustments, raise the roof and check if the door fits correctly. If further adjustments are needed, lower the roof again and repeat the process as necessary until the door shuts correctly without any binding. Remember to readjust the tension cable when you are done.

It is worth noting that minor differences in roof height, less than 1 inch, may not be worth adjusting. Additionally, always ensure that your camper is level before making any adjustments, as an uneven surface can affect the accuracy of your measurements.

If you own a StarCraft pop-up camper, you may need to adjust the roof height cable to raise or lower the roof. This process involves adjusting the cable at the whiffletree, which is located at the front of the camper. By adjusting the cable, you can control the height of the roof.

In conclusion, adjusting the height of a pop-up camper roof is a relatively easy task that can be accomplished by following the steps outlined above. Remember to work on a level surface and take precise measurements to ensure the desired roof height is achieved.

Repairing water damage to a pop-up camper roof

Water damage to a pop-up camper roof can be extensive and may require a full roof rebuild. Here is a detailed guide on repairing water damage to a pop-up camper roof:

Remove the Pop-Up Camper Roof:

• Take out the vinyl trim insert and unscrew the exterior trim.
• Assess the water damage by observing the condition of the screws. Rotted screws indicate rotting wood.
• Remove all screws, using a combination of tools such as a pry bar, pliers, and a screwdriver.
• Scrape off old putty tape and clean the area with mineral spirits and steel wool.
• Lift the skin to inspect the extent of water damage to the wood structure.

Detach the Canvas and Remove the Roof:

• Unscrew the canvas from the inside of the camper. Take pictures of the brackets for reference during reassembly.
• Detach the canvas by unzipping each corner and sliding it out of the track.
• Lower the roof using 2x4 lumber to support it and release tension from the cables.
• Unscrew the bolts attaching the lift arms to the roof and carefully slide off the arms.
• With the roof supported, lift it off the body of the camper and place it upright.

Remove Rotted and Water-Damaged Wood:

• Remove the RV vent, metal trim, and caulk or butyl tape from around the roof's outside.
• Flip the roof over and sweep the floor to prevent dents and damage to the thin aluminium skin.
• Take off the remaining trim, brackets, interior lighting, and vent garnish.
• Gently tap and pry off the side panels, ceiling, and panelling. Use a router to make channels for easier removal.
• Scrape off the insulation foam and remove the roof framework with a crowbar and rubber mallet.
• Soak wooden pieces with acetone to aid in their removal. Wear a respirator and gloves for safety.

Rebuild the Roof Structure:

• Assess the damage and decide whether to replace individual pieces of wood or rebuild the entire frame.
• Cut and attach new wooden boards to the existing ceiling frame using wood glue and screws.
• Use the old roof sides or aluminium skin as a template to create new side panels.
• Wrap new aluminium sheeting around the side boards and attach it with contact cement.
• Predrill camper lift holes and attach the side boards to the lift arms.
• Attach the front and rear roof sides to the side panels with wood glue and trim screws.

Reattach the Roof to the Camper:

• Place the rebuilt roof on top of the camper and screw through the side boards into the ceiling frame.
• Use a sealant, such as Dicor Lap Sealant, on the screws for added protection against water.
• Attach the aluminium roof skin to the front and rear wood boards with contact cement.

Seal Camper Roof Seams to Prevent Future Leaks:

• Clean the roof surface by removing any old tape or caulk.
• Apply a waterproof sealing product, such as Eternabond Tape, to the seams to prevent future leaks.

Reattach the Pop-Up Canvas:

Attach the canvas back to the roof lifting brackets using new, self-drilling stainless steel screws.

Detaching the canvas to remove the roof

If you find that you need to replace a significant amount of wood on your pop-up camper roof, you must detach the canvas before removing the roof. First, unscrew the canvas from the inside of the camper. The canvas is typically attached to metal strips that are screwed into the sides of the roof. Taking pictures of the brackets around the entire inside perimeter of the roof will help you remember how to put everything back together.

After detaching the canvas, unscrew the four lifting brackets from the sides of the roof frame. These are usually attached with bolts and nuts on the inside of the camper. To keep the roof in place while you work, use 2 x 4s to support it. Once everything is disconnected from the main body of the camper, carefully remove the roof and place it on a pair of sawhorses next to the camper.

Now that the roof is off, you can decide whether to remove the skin, foam, and framing lumber and rebuild from scratch or just replace the pieces of wood that are no longer structurally sound. If the water damage is minimal and the wood is still sturdy, you may be able to skip ahead to sealing the camper roof to prevent future leaks.

Reattaching the canvas

After making the necessary repairs to the roof structure and sealing the seams, you can reattach the canvas. Because some of the old screws may be rusted due to water damage, it is recommended to use new, self-drilling stainless steel screws to attach the canvas bracket to the wood frame.

Adjusting the roof when it's uneven front to back

Adjusting the roof of a pop-up camper when it is uneven front to back can be done by following these steps:

First, identify the extent of the unevenness by measuring the height from the sill to the lip at both the front and back of the camper. If the difference is less than 1", it may not be necessary to adjust. However, if the difference is more significant, or if the door is binding, an adjustment may be required.

To make the adjustment, start by raising the roof just enough to pull out the beds. Then, lower the roof onto the beds to create some slack in the cables. Under each corner of the roof, you will find a pulley with three holes. These holes allow for height adjustments. Check if the pulleys are all in the same position, as someone may have adjusted only two of them.

To adjust the height, remove the clip and push up the pin on the pulley at the sagging end of the roof. Make the necessary adjustments and reinstall the pin and clip. Each hole adjustment changes the height by approximately 1 1/2". Repeat this process as needed until the roof is level.

Finally, readjust the tension cable (red cable in the corner) when you are done. It is recommended to make these adjustments with the roof down or blocked up to take the load off the cables.

Fixing the skin of a pop-up camper roof

Step 1: Remove the Exterior Trim

The first step is to remove the vinyl trim insert that covers the screws. This trim should pop out easily when pulled. Then, use a screwdriver to remove the screws. If the screws are rusted or rotted, you may need to use a combination of tools such as a pry bar, pliers, or a rotary tool to remove them.

Step 2: Assess the Water Damage

Once the screws are removed, use a metal putty knife or scraper to remove any old, sticky butyl tape. You can use mineral spirits and fine mesh steel wool to remove excess residue. At this point, you can lift the skin to assess the condition of the wood underneath.

Step 3: Detach the Canvas

If extensive wood replacement is required, detach the canvas from the inside of the camper. Take pictures of the brackets to use as a reference when reassembling. Unscrew the canvas from the metal strips, and then remove the lifting brackets. Use 2x4s to support the roof while detaching the brackets.

Step 4: Remove Rotted and Water-Damaged Wood

If the water damage is severe, you may need to remove all four sides of the roof, as well as the outside edge framing. Cut away the 1x2 pieces that are still attached, being careful not to cut through the aluminium skin.

Step 5: Build or Repair the Ceiling Frame

To rebuild the ceiling frame, attach new 1x2 boards to the existing interior ceiling frame using wood glue and screws.

Step 6: Rebuild the Roof Side Panels

Use the old sides as a template to create new side panels. You can use plywood or thicker boards, but if you use thicker boards, you will need to notch away 1/4" from the ends where the boards meet to ensure a proper fit. Wrap new aluminium sheeting around each side board and attach it with permanent contact cement.

Step 7: Reattach the Roof to the Camper

Place the roof on top of the camper and screw through the side boards into the ceiling frame using trim screws. Dip each screw in a sealant like Dicor Lap Sealant to protect against water.

Step 8: Seal the Camper Roof Seams

Clean the roof surface thoroughly, removing any old tape or caulk. Apply a waterproof sealing tape like Eternabond Tape to the seams to prevent future leaks.

Step 9: Reattach the Canvas

After the roof is attached to the lifting brackets, reattach the canvas using new, self-drilling stainless steel screws.

Step 10: Cover Interior Damage (Optional)

If there is water damage to the interior of the roof, you may want to cover it up. You can find a tutorial on using glue-up ceiling tiles to give the interior a new look.

Step 11: Weather Stripping (Optional)

If desired, you can add a rubber gasket to the bottom of the new roof sides using gasket adhesive.

Tips for Removing the Aluminium Skin

If you need to remove the aluminium skin, try using a heat gun or hair dryer on high heat to loosen the adhesive.

Quick Fix for a Cracked Roof

For a quick fix, you can use epoxy and fibreglass tape to mend a cracked roof, providing strength to the repair. Alternatively, Sikaflex 221 is recommended for bonding and sealing.

Frequently asked questions