Originally Posted by SidecarFlip
Why not re-roof it with a single sheet of 16 or 18 gauge aluminum and be done with it?... if out of warranty...
Many people have discussed just that in some of the popup forums over the years. The problem always was sourcing out a sheet large enough that did not cost a small fortune to buy and ship. You would need an 8'x14'+ sheet for a 12' box like the OP's.
For a few years Coleman/Fleetwood popups had one piece aluminum roofs after their ABS roof debacle. Lots of other brands used aluminum in the past but were 2 piece with a mill seam down the center. Everyone then went to Filon most likely because it's cheaper.