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Old 09-20-2009, 02:45 PM   #11
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Update for today. My 8 yr old daughter has been helping me every step of the way, every day. what a trooper she is. Loving every minute of it and she never wants to stop.

Today I had several conversations with Forrest River parts, and Steph was great at getting back to me almost instantly. I've ordered all new lift springs, telescoping tubes, chain connectors and a new crank handle. All should be enroute to me tomorrow. A lot of work to install it I'm sure, but it should be popping up like new after that. Surprisingly, parts weren't very expensive.

Last night I finished up the lap joint on the sides, added 6 wooden 3/8 dowels to each for rigidity. Looks good I think. Splice joint is about 18 inches back from the end to avoid landing directly where the uprights bolt to the roof.



Couldn't locate and blue Formica in stock anywhere, so I settled on a tan marble. Blends in fine with the existing roof material and the counters/floor etc. In reality you won't be able to see much of it when the pup is raised as the canvas and tracks cover most of it, but at least I know its there. Makes be feel better knowing there will be less exposed wood. Used best quality contact cement I could find, and then routed the edges to finish it off.



Being over 8ft long, this has a butt joint as well.

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Old 09-20-2009, 02:46 PM   #12
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No progress yesterday. Today though, I received my parts from Forrest River. New lift springs, telescoping tubes, chain connectors and a new crank handle all arrived in one box. Not looking forward to crawling into those tight cubby holes to work on the lift system again, but it will be worth it in the end. Probably tomorrow's project.





Tonight I mounted the four side panels. Interior trim looks good. Everything seems to fit okay, so far.

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Old 09-20-2009, 02:47 PM   #13
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I opted only to use the formica on the side panels, leaving the end panels raw wood.



Having peeled back the rear sheathing, I remounted the exterior trim temporarily to make sure the aluminum extrusion and sheathing fit back together well.



What adhesive should I use to adhere the aluminum to the wood? Its not sitting flat as it is and I think bonding it to the wood may look better. Contact cement okay?

I wish I thought about ordering the bottom gasket with my order. Doubtful the local dealer will have it in stock. I'll replace it later I suppose.

That's it for today. Tomorrow morning I'm off to see if my local dealer has Eternabond tape and some rubber roof coating, like KoolSeal. If I am really lucky, they will have aluminum material to fix the damage in the front. We'll see.

What type of silicone sealant should I use for the exterior trim, or what sealant to use if silicone is not a good idea?

Is there a special way (tool to use, or some type of liquid release agent) to make removing the old silicone easier? Some of it peels off easily, but in other areas it has a super strong bond. Must be different types.
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Old 09-20-2009, 02:47 PM   #14
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I worked most of the weekend rebuilding the roof, but didn't take pictures along the way. Roof is re-assembled, except for corner caps and bottom gasket.

This is probably a good place for a before/after shot.

BEFORE:


AFTER:




BEFORE:


AFTER:
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Old 09-20-2009, 02:48 PM   #15
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When I visited the local RV shop, they had lots of advice. I haven't decided what the best long term solution is fo the front sheathing, so I opted for the less perfect EPDM patch for now. I looks okay.

The perimeter trim was sealed with butyl tape and silicone. I have replacement corner caps, bottom seal, and screws cover strip on the way from Forrest River.

One of the four new corner posts was assembled at the factory incorrectly. The mounting hole at the top of the telescoping post is 90 from where it should be. The post assembly is riveted together so I cannot easily remove the smallest rod to reposition it. I'll see what they they recommend.



Tonight I installed the three good corner posts. Hopefully this weekend I will have time to work on the lifting system and re-install the roof.

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Old 09-20-2009, 02:49 PM   #16
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Good news Forest River is sending me a replacement lifting post. No problemo.

Tonight I moved the roof outside, and brought the trailer inside, to move ahead with the lifting mechanism.

First step was to remove all the trim from the top edges, and then remove the bunk ends.





Then focussed my attention on the front lift mechanism, and removed the door side cabinet to make it easier. Just a few screws and out it came.



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Old 09-20-2009, 02:49 PM   #17
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The master link I had repaired had broken again, and I have replacements now. I took the adjustable pulley end of the mechanism out.







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Old 09-20-2009, 02:50 PM   #18
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The spring and chain traveler on this end looks good. Here you can see how the spring attaches, and one of many master links on the chain (4 on each end).



This looks like a lot of work, but its not too bad. Just a bunch of screws. Dis-assembly probably goes a lot quicker than re-assembly.

The main camper is in great condition. The walls show almost no impact from moisture. Floor is not perfect, but its not in need of any attention at this time.
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Old 09-20-2009, 02:51 PM   #19
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Continuing with pics. After removing all of the front interior trim and lift system, I cleaned up the factory wiring with ties.





The cotter pin was missing from the front tensioner shaft. If you look at the angle the drilled it at, I can see why. You'd never be able to get one in.



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Old 09-20-2009, 02:51 PM   #20
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I re-drilled the hole, straight. Fits better now.



While I had the ratchet mechanism apart, I noticed the washer and pin on the end were in poor condition.



I wasn't sure what the washer was supposed to look like, but I machined a top-hat stye bushing in stainless and installed a new pin. This took a lot of slop out of the ratchet. Just like new again.



Someone mentioned rusting lift mechanisms, and this one had a bit of surface rust. Wire brushed it, then painted it to help slow down the corrosion. You can see the new 1/2" conduit tie rod installed as well. Installing new master links on the chains was a bear, to say the least. Its hard to get tiny parts in there with fat fingers. All lift posts are new, the springs are re-used for now, with new master links on the chains and new fasteners everywhere.

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