Originally Posted by skylilymd
For anyone who is curious - this is what it looks like inside the front bunk roof (note the styrofoam is what makes the roof crown - the aluminum supports are flat - you can't see in the pics but the screws from the front cap to the fiberglass roof are pulled out of the luan)
So you pulled your ceiling panel out? That had to hurt to do that
I've made a number of postings
on my leak issues so I'm not stranger to the roof/ceiling leaks (and other leaks).
My last efforts to get help from Forest River ended with the familiar get it fixed and send us the bill and we will decide our responsibility.
Not bashing FR, Joshua or Brian but all the might of strength I can muster I can't bite my tongue to prevent me from saying that the roof design is bad engineering - particularly at the front fiberglass cap to the coach roof. This transition needs a far better system.
I'm not a degreed engineer however the simple physics - we know that a transition needs more than just the lip of material mechanically fastened (screwed) and a bead of sealant for weatherproofing.
Ideally the roof should be a monolithic system but this is not possible in the current assembly method of these RV's. The next best system would be a substrate flashing with a support bridge - another run of a ceiling joist at the overlap point of the fiberglass cap and the fiberglass roof. These two materials are mechanically joined into the new joist. In this way it secures the material to minimize separation caused by stress, vibration and thermal changes.
It's discouraging to have these leaks - especially in coaches so new. The front caps have changed a couple times since my model year but the transition piece remains the same. Reviewing the forum - this is not a new problem. I'm surprised that FR hasn't done much to improve this one area.
I have the similar soft spots but it is mostly the adhesive that has separated from the fiberglass roof and the luan substrate. I thought maybe to fix it from above, pulling the fiberglass and cutting back the wood or just re-gluing if that is all it needs. I hate to think what you will have to do to restore the interior after removing the your panels.
How did you remove the panels - old fashion pulling? What are your plans from this point?
I'm curious, I'm trying to decide my next step which includes quiting RVing. I've never worked so much on something so new and expensive. It has NOT been a recreational