Coleman popup ABS roof repair on a 2000 Westlake

Kdague

Member
Sep 15, 2020
52
I thought the same thing. A bunch of my cracks appeared while it sat in the hot sun for a month on the side of my house when I was redoing the front box. Before u start make sure u clean the roof REALLY WELL and get all the dirt and mold off the roof. You wouldn’t believe all the cracks that showed up once I did that. I wasted 40 hours trying to drill those holes and fill with ABS MEK. Glueing the ABS back down doesn’t work. Look for any place that water could get in. If the cracks are much longer than an inch or if they are on the top of roof the water is probably getting in. If the cracks are just on the side like the first ones I had and nothing on top you might be ok. I wish I would have tried doing it 5 years ago when I only had the 3- 4” cracks on one side, it may have extended the roof life but from some of the threads I’ve read it sounds like more would’ve showed up eventually. Good luck with whatever u try.
 

Rachel Andrews

New Member
Jan 31, 2021
4
I had the box made by a mechanical contractor. They are usually good with metal fabrication if u find a larger commercial union employed company. I will try and write a thread on it in the next couple of weeks and post pics if that would help. I followed a lot from this lady here. https://www.popupportal.com/threads...torage-trunk-for-our-2003-coleman-utah.60457/
And she has a blog page here with more pics and some more info http://popupperegrination.blogspot.com/
I did some of the adjustments that she suggests, if you read through her threads and then added some of my own twists in order to have it the way I want. I can’t tell you how much it cost to have that built but I’m guessing it would be around 1200 to 1800 depending on who u go to. Maybe cheaper. That’s only having the box made, not installed. I see she paid a 1000 almost 9 years ago. Make sure it’s aluminum for the weight. When I do a thread I’ll try and make it as detailed as possible and post a link here.

Just wanted to check in and see if you happen to have the specs for your box. We have a fabricator that can do it and want to get a price. We have a 2003 Westlake, so we were thinking the specs should be the same. Thank you so much!
 

Kdague

Member
Sep 15, 2020
52
Yeah sorry, life has been really busy around here. Hard to believe considering we have -5 highs but, I will try and get it done by end of next Friday, I hope. Don’t hold it against me if I don’t.
 

Indyandy474

Member
May 8, 2021
35
Spencer Indiana
ECAC26ED-90D9-4C61-AD59-33BA0CD6E247.jpeg Removed the outer layer on the top 5 years ago. I was done with patching. Once it starts to deteriorate it won’t stop, it just gets worse. This year just a coat of Diamond Hard acrylic enamel and a roof seal repair and I am good to go. 91E1198D-12BA-462F-91AA-5353BB85E281.jpeg ECAC26ED-90D9-4C61-AD59-33BA0CD6E247.jpeg
 
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Phisherman

New Member
Aug 13, 2020
9
Colorado
Kdague- amazing work. I am going to follow your detailed approach this week as I replace the roof on my '98 Coleman Fleetwood Grandview. Did you replace the roof gasket seal? And if so, did you get the one for old ABS style roof or the other version that is for the metal type roof? Just curious since mine is falling apart and I don't know the ABS replacement gasket will fit since I have torn off all the ABS :)
 

Kdague

Member
Sep 15, 2020
52
410AF1DE-04EE-407E-9B22-40B5E3AB0402.png This is what I bought and where I bought them from. You can squeeze the molding side in a little if u need to. I would suggest watching a video on how to install it.
That’s how I did it.
 

traveljunkie

New Member
Aug 17, 2020
7
Chicago

hey there, so I’m a newbie here please be patient. I took my camper out recently and the entire white vinyl top flew off on the highway. It was an awful experience altogether. What was underneath looks a lot like this picture and was very sticky. As soon as I could get it parked I put a tarp over it. It did get rained on a bit. I wiped it down and tried my best to keep it try. I noticed some bubbling I suppose where the moisture was. Can this still be used? I don’t think there are any holes in the roof itself but how exactly would I know? Could I just sand it, clean it, and use the GG coating at this point? Or is it a lost cause if it got wet?
 

Kdague

Member
Sep 15, 2020
52
hey there, so I’m a newbie here please be patient. I took my camper out recently and the entire white vinyl top flew off on the highway. It was an awful experience altogether. What was underneath looks a lot like this picture and was very sticky. As soon as I could get it parked I put a tarp over it. It did get rained on a bit. I wiped it down and tried my best to keep it try. I noticed some bubbling I suppose where the moisture was. Can this still be used? I don’t think there are any holes in the roof itself but how exactly would I know? Could I just sand it, clean it, and use the GG coating at this point? Or is it a lost cause if it got wet?
Yep check for inner cracks and breaks. If all is good sand down. Fill with bondo if u want (I think that’s kind of a yes I want it smooth or I don’t care kind of choice it’s up to u). I don’t think the water really hurts the top unless it’s prolonged for a long time but I’m not sure. I do suggest that before u put GG or what ever u use that u clean and wash the top multiple times and let it dry well before u start. If the tops not clean the GG won’t stick well. Also try and do it when it’s not real humid out. Mine took twice as long to dry because of all the humidity.
 

Indyandy474

Member
May 8, 2021
35
Spencer Indiana
I used KoolSeal roofing sealer, it’s white and substantially less expensive than GG. I put 4 coats on and that lasted 5 years before I recoated with a latex acrylic white semigloss. It looks great. Yes, I would fill depressions and imperfections before. Just be sure the core is clean before you apply anything. Good luck and let us know how it went.
 
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sweets

New Member
Apr 25, 2010
4
Maryland
This is fantastic. You did a great job. I am glad I found this idea for consideration before doing the MEK, ABS goo, fiberglass cloth and the Grizzly Grip technique. I have cracks in the roof of my 2000 Coleman Santa Fe but no delamination taking place as of yet. The roof seal is still sound as well. Overall, I don't feel like my roof is in an advanced enough state of deterioration to do this repair.

Do you guys feel that using properly applied eternabond tape can be a viable method before taking more dramatic measures? I'd like to see what happens before I go all in with this more extensive repair. Thank you.
 

sweets

New Member
Apr 25, 2010
4
Maryland
Did you go the tape and GG route? My 2000 Fleedwood Bayside is not too bad but I want to stop the cracking before it gets worse. I was planning on epoxying the loose pieces and GG over it. But I've read mixed msg about the success of glueing.
Would love to know if it worked out.
Thanks
Anne
 

Indyandy474

Member
May 8, 2021
35
Spencer Indiana
I have not as yet. I have a canopy that I have been using instead. The canopy bag that stores the awning has disintegrated so I have to make another bag before I can re-install.
 

Sjm9911

Super Active Member
May 31, 2018
12,689
Nj
Did you put the awning rail back on? I was wondering how that would be securely attached with the ABS roof removed?
I didnt do it, but if i did it would be the aluminum awning rail, and a backer plate or plates inside the camper. Drill through it and sandwitch the foam with the metal plate and aluminum rail. Bolt it on. Use dicore in and around the holes.
 

Kdague

Member
Sep 15, 2020
52
Mine never worked. It was pretty much shot when I got the camper. I’m not sure about attaching it with glue or double sided 3m tape. I don’t know if I’d trust it to stay. I would do like sjm9911 suggests if I was going to add one. I’ve never really needed it. I repaired the one bracket that I removed incorrectly (for securing the top for travel) that way and it seams to hold up just fine.
 




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