Photos of Roof Repair & Replacement

Started by The_Handier_Man1, November 11, 2008, 08:32 PM

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Just wondering how this repair has held up over the past couple of years?  Would you do the same if you had to it all over again?  I recently purchased a 1975 19' Winnebago and need to do the same type of repair.



I used plywood with the snow roof product.  I think it works great and is something I can repair if a tree limb or something tries to go thru it.  No metal is on the roof.


Am I to understand that you put plywood over this rib structure, and painted with Kool Seal primer followed by Kool Seal elastomeric?

Just trying to understand the process... as my 75 Indian is currently a convertible... this might steer me a different way.

I'd never considered losing the metal altogether.

Impressive collection of photos. :)ThmbUp



hi dude
you have been my inspiration to tear off my old roof and tackle the replacement as an engineering project instead of good ol carpentry, basically it involves 15each  2"X1"X16gauge rectangular steel box section spanning the width of my 25' chieftain. They were cambered to about 3" at the centres on a power roller. A central and two side bearers tacked to the existing angle section (MIG welder)  I then clad the roof with 16gauge structural aluminium alloy. NO metal fixings, all bonded down with SIKAFLEX 291 structural polyurethane  panel adhesive and insulated on the inside with 3/4" celotex board.......not bad for a foreigner living in the UK ?


The aluminum was bought at Great Dane  it is 105 inches wide and you could get whatever length that you wanted.   This is the same aluminum that is used for tractor trailer roofs.   The cost...after bargaining....was $217 for a 17 foot piece.   Alan liked this best because there are NO SEAMS therefore less chance of roof leaks. 


Quote from: ohhmom on February 18, 2009, 11:50 PM
We have purchased sheet aluminum and we are going to place that on top of the plywood is all one piece of aluminum...and then we will work on the coating. 
So where did you buy the aluminum, size, thickness and the big question,  how much did it cost?  I am sure others want to know,  Les


Thanks for all your help on this one...Alan is half way through with putting on the plywood on the top.   We have purchased sheet aluminum and we are going to place that on top of the plywood is all one piece of aluminum...and then we will work on the coating.   You and Wilbur have been a life saver!


When I finally find my old backup disks of all the pictures we had on the old site of The Ark (before sucky MSN put on photo limits and I had to pare down my albums) I'll have to post pics of how NOT to repair a!  Outstanding job, Les!

Fortunately our 77 Itasca still has a perfect roof with absolutely no sags at all.  The original owner had owned other flat roof Winnies before he bought the Itasca new in 77, so he wisely added a crossmember and roof support at the front AC unit...the back AC unit is so close to structural walls (the closet on one side and the corner of the bathroom on the other) that it needed no further support.  Also, I guess, at least with the newer nose style they started using on the Itasca line in 77, they no longer used seamed panels on the roof...the roof is one solid smooth sheet of corrugations and no seams.

We I bought it 2 years ago, it had never even been coated...with ANYthing...its whole life!  Of course, most of that life was spent in Death Valley, so Excalibur hardly ever saw any rain.

The first thing I did when I bought her was to scrub the roof down with TSP, rinse it off clean, let it dry, sealed every vent and whatnot with Acylic Seam Sealer (Kool Seal brand), and then coated the roof with several coats of white Kool Seal.  No leaks from the roof to date, and I finally tracked down the leak over the dashboard...water was coming in through one of the front marker lights!

Anyway, I'm rambling again...AWESOME job Les!

Kev and Patti, the furry kids, our 1981 Ford F-100 Custom tow vehicle, and our 1995 Itasca Suncruiser Diesel Pusher.


I used 1/2" plywood and only the snow roof products over the ply.  There is a seam tape to be used on the edges of the ply with the undercoat material.  Sorry no free gifts other than the pictures and advice,  Les


This will be a great resource when I need to tackle my '75 Brave in the spring.  What did you use for ply?  And what is on the ply? (Just primered and painted with the snow roof stuff?)


Sent: 10/28/2008

Here is a detailed photo album of my D24 Indian, "Wilbur", roof replacement from tear-down to re-build.  Curved trusses were used to cure the "flat roof syndrome" and a number of other modifications made to improve upon the original design.  Very detailed photos of every aspect and phase.

A must see!