Repairing Pop-Up Camper Plastic: Easy Diy Guide

Repairing the plastic on a popup camper is a common issue faced by many owners. The plastic on these campers can get damaged due to age, accidents, or wear and tear. There are several methods that can be used to fix this issue, depending on the extent of the damage. For small cracks and holes, using duct tape or Gorilla Tape can be a quick and inexpensive solution. For more extensive damage, methods such as fiberglass repair kits, epoxy, or replacing the entire panel may be necessary. It is important to assess the damage and choose the most suitable repair method to ensure a durable and aesthetically pleasing result.

Repairing cracks in the plastic body panels of a pop-up camper

Step 1: Assess the Damage

Before beginning any repairs, it is important to assess the damage to determine the best course of action. Minor cracks and holes can often be repaired with a simple filler or epoxy, while more extensive damage may require plastic welding or even replacement of the entire panel.

Step 2: Clean the Surface

Use a wax and grease remover to clean the plastic surface. This will ensure that the repair material will adhere properly. You can also use window cleaner or soapy water for this step.

Step 3: Prepare the Crack

If the crack is small, you may be able to simply fill it with an epoxy or plastic welding rod. For larger cracks, it is recommended to cut a V-shaped groove along the crack on both sides of the panel. This will provide more surface area for the repair material to adhere to.

Step 4: Apply the Repair Material

If using an epoxy or filler, simply mix the material according to the instructions and apply it to the crack, making sure to fill it completely. If using a plastic welding technique, you will need to use a plastic welder or soldering iron to melt the filler rod into the crack. You can also use a piece of the existing bumper as the filler material, ensuring compatibility.

Step 5: Sand and Smooth the Repair

Once the repair material has dried, use sandpaper to smooth out the repair. Start with a coarse grit sandpaper and gradually work your way up to a finer grit. This will help to create a smooth, even surface.

Step 6: Prime and Paint (if necessary)

Depending on the extent of the repair and your desired finish, you may need to prime and paint the repaired area. Make sure to use an adhesion promoter to ensure that the paint adheres properly to the plastic surface. Spray-on bed liner can also be used to recreate the texture and grain of the original plastic.

Alternative Methods

There are also alternative methods for repairing cracks in plastic body panels, such as using duct tape, flexible cutting boards, or fiberglass repair kits. These methods may be more affordable or accessible, but may not provide as durable of a repair.

Removing and reattaching body panels

The body panels of a pop-up camper are attached with screws along the top and bottom. To remove them, first remove all the lights along the camper by popping off the lenses, which are attached with pop rivets. Drill out the rivets and then remove all the screws from the top of the panel. It is important to label everything that is taken off the camper to make it easier to put back together. Put all the screws in Ziplock bags and label them.

At the bottom of the camper, there are screws and washers holding the panels in place. Simply remove these and the body panels can be taken off. There may also be some sort of adhesive, such as silicone caulking, between the metal plate and the body panel. This can be loosened with a couple of plastic putty knives.

To reattach the panels, simply follow the removal process in reverse.

Repairing holes in the plastic of a pop-up camper

Using Methyl Ethyl Ketone (MEK) and ABS Plastic:

• MEK is a solvent that dissolves ABS plastic. You can purchase MEK at hardware stores like Lowe's or online through Amazon.
• For repairs, you'll need ABS plastic pellets or granules. Some sources suggest using plastic airsoft BBs, while others recommend Lego pieces or white plastic spoons.
• Mix MEK and ABS plastic in a glass jar with a tight-fitting lid. Experiment with the ratio to achieve a "goo" consistency similar to white glue.
• Apply this mixture to the cracks and holes in your camper's plastic panels. It will dissolve the plastic and create a strong bond.

Fibreglass Repair:

• For larger holes or more extensive damage, fibreglass repair is an option. You can purchase fibreglass repair kits from auto repair stores.
• Sand the damaged area and use a fibreglass tape and adhesive to create a patch.
• Apply several layers of fibreglass cloth and epoxy resin to create a sturdy repair.
• This method is time-consuming but effective, and the materials are lightweight and waterproof.

Bondo or Auto Body Filler:

• Bondo is a type of putty used in auto body repairs. It can be applied to fill holes and reinforce damaged areas.
• Sand the repaired area to match the contours of the camper.
• Keep in mind that Bondo may not adhere well to ABS plastic over the long term.

Temporary Fixes:

• For a quick and inexpensive solution, duct tape can be applied over holes and painted to match the camper's colour.
• Clear nail polish can be used for small tears in window screens.
• Gorilla Tape, a clear and durable tape, can be used to cover holes and cracks.

When repairing holes in the plastic of your pop-up camper, always wear protective gear, including gloves and eye protection. Ensure adequate ventilation when working with chemicals. If you're unsure about the extent of the damage or the best repair method, consult a professional or seek advice from a specialised forum or community.

Repairing torn plastic windows in a pop-up camper

Step 1: Assess the Damage

Before beginning any repairs, it is important to carefully inspect the torn plastic windows and understand the extent of the damage. Look for any cracks, holes, or tears near the seams where the plastic meets the canvas. Take note of the location and size of each issue. This will help you determine the best course of action for repairs.

Step 2: Prepare the Materials

Depending on the severity of the damage, you may need to gather different supplies for the repair. Here are some commonly used materials for fixing torn plastic windows:

• Clear vinyl repair kit: This kit provides the necessary tools to patch small tears and holes in the plastic.
• HH-66 Vinyl Cement: HH-66 is a strong adhesive specifically designed for bonding vinyl and other plastics. It is ideal for repairing larger tears or reattaching zippers.
• Plastipane vinyl: This is a clear, flexible vinyl material that can be used to create custom patches for torn windows.
• Hand-held stitcher or sewing machine: For more extensive repairs, you may need to sew new vinyl patches onto the existing windows.
• Clear repair tape: In some cases, clear repair tape can be a quick and effective solution for sealing small tears.

Step 3: Remove the Affected Window Panel

Before proceeding with the repairs, carefully remove the canvas section containing the torn plastic window. This will give you a flat surface to work on and ensure that your repairs are precise and secure.

Step 4: Perform the Repairs

There are several methods you can use to repair the torn plastic window, depending on the type and extent of the damage:

• For small tears or holes: Use a clear vinyl repair kit to patch the affected area. Follow the instructions provided with the kit for the best results.
• For larger tears: Apply HH-66 Vinyl Cement to bond a patch of plastipane vinyl over the tear. Cut the vinyl to the appropriate size and shape, then carefully adhere it to the torn area.
• For detached zippers: Use HH-66 Vinyl Cement to reattach the zippers to the plastic window. Ensure that the zipper is properly aligned before applying the adhesive.
• For extensive damage: Consider sewing new vinyl patches over the torn areas. Cut the vinyl to the required size and shape, then use a hand-held stitcher or sewing machine to securely attach it to the window.

Step 5: Reattach the Canvas Panel

Once the repairs are complete and the adhesive is dry, carefully reattach the canvas panel to the pop-up camper. Ensure that all fasteners, zippers, and seams are securely in place.

Step 6: Test and Enjoy

After completing the repairs, test the functionality of the pop-up camper. Set it up and carefully inspect the repaired window for any signs of ongoing damage or leaks. If everything looks good, you can now enjoy your pop-up camper with renewed plastic windows!

Repairing wood rot and side seams in a pop-up camper

Step 1: Assess the Damage

Before beginning any repairs, it is important to assess the extent of the damage. In the case of wood rot, determine how much of the wood needs to be replaced. For side seams, check if the issue is simply a seam coming undone or if there is more extensive damage.

Step 2: Gather Supplies

The supplies you will need depend on the specific repairs needed. For wood rot, you may require materials such as deck railing, wood screws, mould and mildew cleaner, and sealant. If you are repairing side seams, you may need items like Eternabond, side seams for your camper brand, a screwdriver, butyl putty, and a vinyl insert.

Step 3: Remove the Affected Area

If you are repairing wood rot, you will need to remove the affected wood. Use a screwdriver or other tools to carefully take apart the area and expose the damaged wood. For side seam repairs, remove the screws, brake lights, and any other components that are holding the side seams in place.

Step 4: Clean and Treat

If there is any sign of mould or mildew, treat the affected areas with a mould and mildew cleaner. This will help prevent further growth and ensure a clean surface for repairs. It is also important to address any pest issues, such as ants, by spraying appropriate treatments.

Step 5: Replace and Reinforce

Replace any damaged wood with new pieces of deck railing or other suitable wood. Reinforce the structure with wood screws to provide additional support. For side seams, replace the old seams with new ones specifically designed for your camper brand.

Step 6: Seal and Protect

Use a sealant, such as Flex Seal, to treat the edges of the wood and protect it from moisture. This will help prevent future wood rot and ensure the longevity of your repairs.

Step 7: Reassemble and Finish

Reattach the side seams, brake lights, and any other components that were removed. Finish by reapplying caulk around the seams and lights for a smooth and sealed finish.

Tips for Success:

• Be organised and take your time.
• Work with a friend or two; more hands make light work.
• Keep your butyl tape in the freezer until you are ready to use it for easier handling.
• Use high-quality brands for vinyl inserts, such as JR Products, for the best results.
• Allow yourself to be creative and adapt your approach as needed.

Frequently asked questions