RV Repair: Yet another roof leak!, pinhole leaks, aluminum sheet


Question
Dave,
    I have a 1989 Coachman Leprechaun.  The camper is a class C, and overall in good shape.  The roof over the cab bunk area is not so good though (rot due to leaks).  I removed the entire insides of the bunk area over the cab, the paneling lined with wall paper, the blue foam, the paneling adhered to the blue foam.  I plan on putting in new beams, foam, and possibly tan-colored bathroom-style fiberglass sheeting (textured in 4X8 sheets) for the interior walls/ceiling to replace the luan thin paneling that had thick wallpaper adhered to it.  As for the aluminum roof...I was able to locate and seal MANY pinhole leaks in the area.  I also tried to seal the seam of the nose-cone/roof.  What I would like to do is put on a new roof for the entire rig.  Any ideas as to the best material?  I would like to have the new material wrap over the edges of the RV...as the old aluminum sheet only ended at the edge- which made a seam, which of course has deteriorated.  I feel if I put a new material over the edges and down the sides of the RV (say 3-4 inches over)...that it might help.  Please let me know what you think. Thank you.  

Answer
Go with a rubber roof. If you are not going to be doing a lot of walking around up there, then you should be able to put it on right over the metal roof. But the best way to do it right would be to remove the metal roof. Then make sure the decking is allright (if not, replace). Rubber roof comes 8.5' wide so you should be able to wrap it down the sides by screwing on gutter rail after it is glued.
Here is how to install a rubber roof:
I would plan on about a weeks time for 2 people who have never attempted this. You will have to remove everything that is attached to the roof first. Then remove the metal roof. Next you will need to sand the decking to get it ready for the new roof, and put masking tape over the seams where the decking joins. Then you can put the glue down with a brush or roller (roller with a long handle is easiest) and roll the rubber out. It's a good idea to roll the rubber out completely first to make sure that it is square on the roof and then roll it about half way up and start gluing down and then glue the other half. Be careful not to step in the vent holes, etc., while they are covered up. Then all that's left is to remount everything that was previously removed.
Here are some websites for rubber roofs.

www.dicor.com

http://www.pplmotorhomes.com/parts/rv-roofs-epdm-rubber-roof-repairs-1.htm

http://www.jnkproducts.com/liquid-roof2.htm


I hope this helps you out,
Dave

Vote for me for expert of the month if this helps you. Thanks