Pop-Up Camper Roof: Diy Redo Guide

Redoing a pop-up camper roof is a challenging but rewarding task. It typically involves removing the old roof, repairing any structural damage, and installing a new roof. This process can vary depending on the extent of the damage and the materials used, but the basic steps remain consistent.

The first step is to remove the old roof, which may include detaching the canvas, lights, vents, and other fixtures. It is important to assess the damage and determine the necessary repairs, such as replacing rotted wood or fixing water damage. After making the required repairs, the next step is to install the new roof. This typically involves attaching the roofing material, sealing seams to prevent leaks, and reattaching any removed fixtures.

There are various roofing materials to choose from, such as fiberglass, aluminium, or rubber. Each material has its advantages and disadvantages, so it is essential to consider factors such as cost, durability, and ease of installation when making a decision.

Overall, redoing a pop-up camper roof is a complex project that requires careful planning and execution. It can be a rewarding experience for those who enjoy DIY projects and want to give their camper a new lease of life.

Remove the roof

Removing the Roof

The first step in redoing a pop-up camper roof is to remove the old roof. This will allow you to assess the damage and make necessary repairs. Start by removing the canvas and canvas rails from the interior roof, as well as any lights, vents, or other fixtures. If you plan to reinstall these items in the same places, be sure to measure and mark their locations before removing them.

Next, remove the screws from the bottom channel that holds the bulb seal. You can save the bulb seal if it is still in good condition. With the roof now detached from everything but the uprights, enlist the help of a few friends to carefully lower and remove the roof. Unscrew and save the bolts for measurement later.

Remove All Trim and Tear Apart the Roof

With the roof removed, it's time to start disassembling it. Lay the roof on the ground and remove all trim, including the awning rail and corners. Clean off any old butyl or putty tape to ensure a clean seal when reinstalling. Save the side metal pieces to use as a template for the new wood. Measure and mark the location of any vents or other fixtures you plan to reinstall.

Measure, Measure, Measure

Use the side metal panels as a template to trace onto your new side wood boards. Then, measure the distance between the sides to determine the length of the front and back boards. The thickness of the wood may affect how the pieces fit together, so be sure to test the fit before cutting all your pieces. Cut out the sides, front, back, and ribs according to your measurements.

Assemble the Framing

Place the wood pieces into the metal bottom channel to ensure they fit together properly. Make any necessary adjustments, such as sanding down pieces for a better fit. Pre-drill holes and screw the sides to the front and back pieces. Find the center of the sides and attach one of the 2x2 ribs at the center, screwing it into both sides. Depending on your underlayment configuration, you may need to add additional ribs for stability and attachment of the ceiling material.

With these steps completed, you have successfully removed and disassembled your pop-up camper roof. The next steps will involve repairing or replacing damaged components and reassembling the roof.

Repair water damage

Water damage is a common issue with pop-up camper roofs, and repairing it can be a complex and time-consuming process. Here are some detailed instructions on how to repair water damage on a pop-up camper roof:

Assess the Damage:

Before beginning any repairs, it's important to assess the extent of the water damage. Remove the exterior trim by taking out the vinyl trim insert and unscrewing the trim. This will give you access to the structure underneath and help you identify areas of water damage, such as rusted or rotted screws.

Remove the Pop-Up Camper Roof:

If the water damage is significant, you may need to remove the entire roof. Detach the canvas by unscrewing it from the inside of the camper. Take pictures of the brackets to use as a reference when putting everything back together. Unscrew the lifting brackets and use 2x4s to hold the roof in place while detaching it from the main body of the camper.

Repair or Replace Damaged Wood:

Water damage can cause wood to rot, so it's important to inspect the wood structure of the roof carefully. Remove any rotted or water-damaged wood and replace it with new pieces. You may need to cut away damaged wood using a small circular saw, being careful not to cut through the aluminum skin.

Rebuild the Ceiling Frame:

Attach new 1x2 boards to the existing interior ceiling frame using wood glue and screws. This will help reinforce the structure and ensure it is sturdy.

Seal the Camper Roof Seams:

Clean the roof surface thoroughly to remove any old butyl tape or caulk. Apply a waterproof sealant, such as Eternabond Tape, to the seams to prevent future leaks. This tape is flexible and creates a strong waterproof seal.

Reattach the Pop-Up Canvas:

Once the roof repairs are complete, you can reattach the pop-up canvas. Use new, self-drilling stainless steel screws to secure the canvas bracket to the wood frame.

Prevent Future Water Damage:

To prevent future water damage, consider placing U-channels on the interior of the roof to prevent sagging. Regularly inspect and maintain your pop-up camper roof, sealing any cracks or gaps that could allow water ingress.

Seal seams

Sealing the seams of your pop-up camper's roof is an important step in preventing future leaks and water damage. Here is a detailed guide on how to seal the seams effectively:

Clean the Roof Surface

Before applying any sealant, it is crucial to ensure that the roof surface is thoroughly cleaned. Remove any old butyl tape, caulk, or other adhesive residue from the seams and surrounding areas. You can use a metal putty knife or scraper to remove stubborn residue, followed by a solvent such as mineral spirits to wipe away any remaining gunk. This step is crucial, as applying sealant over old adhesive can compromise its effectiveness.

Choose an Appropriate Sealant

There are several options available for sealing the seams of your pop-up camper's roof. One popular choice is Eternabond Tape, a rubberized tape that creates a waterproof seal and flexes with temperature changes. Silicone caulking is another inexpensive and widely available option that can be used to seal seams. If you're looking for a more durable solution, spray-on liners like Line-X and Rhino Liner are an option, though they are more expensive. These liners not only seal cracks but also provide added protection against future damage.

Apply the Sealant

Once you've chosen your sealant, carefully follow the manufacturer's instructions for application. For tape or caulking, ensure that you apply it in a continuous, even layer over the seams, making sure to cover any gaps or cracks. If using a spray-on liner, you may need to stir the contents and work quickly, as the adhesive can dry fast. It is recommended to work in a well-ventilated area and wear protective gear when applying sealants.

Smooth Out Bubbles

After applying the sealant, carefully inspect the seams for any bubbles or uneven areas. Use a roller or a flat tool to smooth out any bubbles and ensure a uniform application. This step is crucial, as bubbles can compromise the effectiveness of the seal and may need to be punctured and resealed if they persist.

Allow for Drying and Curing

Depending on the sealant you've chosen, allow for adequate drying and curing time. Refer to the manufacturer's instructions for specific guidelines. Do not disturb the sealant during this period, as it needs time to set and form a strong bond.

Reattach the Canvas

Once the sealant has cured, you can proceed with reattaching the canvas and other components of the pop-up camper's roof. Follow the appropriate instructions for your camper model to ensure a secure and proper reinstallation.

By following these steps and choosing an appropriate sealant, you can effectively seal the seams of your pop-up camper's roof, preventing future leaks and water damage. Remember to perform regular inspections and maintenance to identify any potential issues and ensure the longevity of your camper.

Re-attach canvas

Re-attaching the canvas is the final step in redoing a pop-up camper roof. Before re-attaching the canvas, you should ensure that the roof is attached to the lifting brackets. If you have replaced the roof, you may need to drill new holes for the wiring. You can then attach the canvas back to the roof, using new self-drilling stainless steel screws to attach the canvas bracket to the wood frame.

If you are reusing the old canvas, you will need to centre the rails as they do not go edge to edge. You can start by putting the canvas in the bottom rail first and then striking the dents with a hammer and an awl. This will sandwich the canvas inside the rail. You can then attach the canvas to the sides and the long single side, folding the canvas into the rails and screwing the rails to the wood frame through the canvas rail insert.

If you are using a new canvas, you can purchase one from Bear Creek Canvas or Canvas Replacements. Both companies have good reviews and offer custom-made canvases based on the camper manufacturer, model year, and style.

Replace rotten wood

Replacing rotten wood on your pop-up camper's roof is a challenging but rewarding task. Here is a step-by-step guide to help you through the process:

Assess the Damage:

• Remove the exterior trim by taking out the vinyl trim insert and unscrewing. This will give you access to the screws and a better understanding of the water damage.
• Take pictures and notes on the locations of water damage, as this will guide your repair process.

Detach the Canvas and Remove the Roof:

• Unscrew the canvas from the inside of the camper. Take pictures of the brackets to remember how to put them back together.
• Detach the lifting brackets from the roof frame. Use 2x4s to support the roof while detaching it from the main body of the camper.
• Place the roof on a pair of sawhorses or a similar stable surface next to the camper.

Remove Rotted and Water-Dampered Wood:

• Assess the extent of wood rot and decide on the scope of replacement. You may need to replace only the affected pieces or opt for a complete rebuild.
• Use a small circular saw to cut and remove the damaged wood, being careful not to cut through the aluminum skin.

Repair or Rebuild the Ceiling Frame:

• If repairing, attach new wood pieces to the existing ceiling frame using wood glue and screws.
• For a complete rebuild, follow the original frame design or consult resources like The Pop Up Princess for guidance.

Reattach the Roof:

• Place the repaired or rebuilt roof back on the camper and secure it with trim screws.
• Dip each screw in a sealant like Dicor Lap Sealant to protect against water intrusion.

Seal Camper Roof Seams:

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

Reattach the Canvas:

Reattach the canvas to the roof using new, self-drilling stainless steel screws.

Remember to work creatively, stay organized, and take your time throughout the process. It is also beneficial to have extra hands to help with the project. With these steps and some dedication, you'll have a like-new pop-up camper roof in no time!

Frequently asked questions