Soft Spot In Roof

[Mr. Goodwrench]

While packing for a recent 4 night outing, I noticed water dripping into the shower. I went up on the roof and as I suspected the skylight had a crack in it. Last year, I found a small crack and used some silicone sealer to repair it. This time, all I had was some Gorilla tape with me so I carefully cut strips of it to cover the crack as well I I could. While doing the repair, I noticed the roof had a soft spot between the skylight and the edge of the roof. The caulking around the skylight appeared to be in good shape.

Two days later at the campground, I used some silicone sealer I had brought with me to seal the crack(s) from inside the trailer after removing the inside trim ring, I could see some discolored wood and some black mold above the ceiling panel. One night later, water was still dripping from the skylight area and all I could do was put a fan in the bathroom to try and keep it as dry as possible.

After returning home, I called a local RV repair shop. They are an independent place, not associated with a dealer. They have a good reputation and I felt I would get a fair estimate to replace the skylight and investigate the soft area under the roof membrane. Without them seeing the problem yet, I asked if after the skylight was removed, if they could just cut the roof membrane straight across from the skylight to the edge of the roof and peel it back to inspect the sheathing, replace damaged wood with new, then glue the flaps of roofing material back down on the new sheathing.

I was surprised when I was told "No, we won't do that. The whole roof fabric must be replaced because it stretches and also particles of the old sheathing will be stuck to it". Without seeing the project yet, he couldn't give me an estimate so as soon as possible, I am taking the trailer to them for evaluation and an estimate.

What are the opinions out there? Does the whole roof need to be replaced to repair some damaged sheathing the size of approximately two by four feet? I have not said anything to my insurance company yet because I was told that water damage would just be considered poor maintenance. However, if the skylight itself had been hit by say a low hanging branch and allowed water to enter and damage the sheathing that repairs would probably be covered. Any thoughts on this repair? Thanks in advance.

 

[Hoopy Frood]

The gist of what they're saying sounds pretty sound to me. But I've never done any real repairs on my roof, so cannot say for sure. I can certainly see if the membrane were well attached, trying to remove only part of it, and repair it, could lead to problems. FWIW, when it comes to repair work on an RV, any silicone sealant is not your friend, it's almost impossible to remove completely if necessary to do real repairs.

 

[downsc123]

I had a slow presentient roof leak likely from day 1 when I bought my current unit in August 2022 - it took many attempts under warranty to find the source of the slow leak. I asked the dealer to ensure that I do not have any roof damage or mold after finally stopping the leak last month. They stated that the roof felt a little soft and that the only way to fix correctly was pull the entire membrane, replaced the affected panel(s) and lay a new membrane. Grand design, while out of warranty, approved the claim and I am getting a new roof. But yes, they can't pull the membrane back partially and then glue it back after the repair - said it would never lay flat and be right.

 

[huntr70]

While packing for a recent 4 night outing, I noticed water dripping into the shower. I went up on the roof and as I suspected the skylight had a crack in it. Last year, I found a small crack and used some silicone sealer to repair it. This time, all I had was some Gorilla tape with me so I carefully cut strips of it to cover the crack as well I I could. While doing the repair, I noticed the roof had a soft spot between the skylight and the edge of the roof. The caulking around the skylight appeared to be in good shape.

Two days later at the campground, I used some silicone sealer I had brought with me to seal the crack(s) from inside the trailer after removing the inside trim ring, I could see some discolored wood and some black mold above the ceiling panel. One night later, water was still dripping from the skylight area and all I could do was put a fan in the bathroom to try and keep it as dry as possible.

After returning home, I called a local RV repair shop. They are an independent place, not associated with a dealer. They have a good reputation and I felt I would get a fair estimate to replace the skylight and investigate the soft area under the roof membrane. Without them seeing the problem yet, I asked if after the skylight was removed, if they could just cut the roof membrane straight across from the skylight to the edge of the roof and peel it back to inspect the sheathing, replace damaged wood with new, then glue the flaps of roofing material back down on the new sheathing.

I was surprised when I was told "No, we won't do that. The whole roof fabric must be replaced because it stretches and also particles of the old sheathing will be stuck to it". Without seeing the project yet, he couldn't give me an estimate so as soon as possible, I am taking the trailer to them for evaluation and an estimate.

What are the opinions out there? Does the whole roof need to be replaced to repair some damaged sheathing the size of approximately two by four feet? I have not said anything to my insurance company yet because I was told that water damage would just be considered poor maintenance. However, if the skylight itself had been hit by say a low hanging branch and allowed water to enter and damage the sheathing that repairs would probably be covered. Any thoughts on this repair? Thanks in advance.

Yep, that's exactly how it has to happen.

The roof membrane is glues down to the OSB sheathing. When you pull it up, it stretches and does pull strands and particles of the old sheathing with it.

If you go the whole roof route, I would suggest a product like RV Armor/Flexarmor. Sprayed on and lifetime guarantee.

 

[dryfly]

I have never understood why rubber roofs cannot be patched. Like vinyl flooring, seems like an area could be cut out and replaced. Then, using metal trim around the perimeter of the cut like the trim on the front and rear caps. At that point use lots of the self leveling sealant on the trim, again just like the way the front cap to roof is sealed.

If replacing I too agree the spray is the way to go.

 

[fmartinmn]

X2 what [MENTION=19127]Hunter[/MENTION]70 said. I chose Flex Armor. Best wishes, Frank.

 

[Second Chance]

Yep, that's exactly how it has to happen.

The roof membrane is glues down to the OSB sheathing. When you pull it up, it stretches and does pull strands and particles of the old sheathing with it.

If you go the whole roof route, I would suggest a product like RV Armor/Flexarmor. Sprayed on and lifetime guarantee.

I would second this approach. If we were to ever need a new roof, this is what I would have done to our unit.

Rob

 

[Mr. Goodwrench]

I have never understood why rubber roofs cannot be patched. Like vinyl flooring, seems like an area could be cut out and replaced. Then, using metal trim around the perimeter of the cut like the trim on the front and rear caps. At that point use lots of the self leveling sealant on the trim, again just like the way the front cap to roof is sealed.

If replacing I too agree the spray is the way to go.

OP here. That's exactly the repair I had envisioned. Just cut out the damaged area of roofing including the wood, replace with new materials, and adhere and cover in the same way the front cap is sealed down. I will try to start a claim with GD since the problem started with what I consider a faulty skylight. Anyone else remember a bunch of threads awhile back regarding what appeared to be a batch of faulty skylights cracking and what about the poor installation techniques using flat head sheetrock screws to fasten the skylight to the roof causing cracks! I think the battle has just begun.

 

[Mr. Goodwrench]

OP again: Just got off the phone with GD Customer Service and as I expected, they take no responsibility for "seal maintenance" after 90 days of purchase. They consider it the owners responsibility to fix any external water intrusion occurrence whether is is due to their negligence or not after 90 days. So if there are any new owners reading this, BEWARE and watch your trailer closely! There is no comparison between the automobile industry and the RV manufacturers.

 

[huntr70]

OP again: Just got off the phone with GD Customer Service and as I expected, they take no responsibility for "seal maintenance" after 90 days of purchase. They consider it the owners responsibility to fix any external water intrusion occurrence whether is is due to their negligence or not after 90 days. So if there are any new owners reading this, BEWARE and watch your trailer closely! There is no comparison between the automobile industry and the RV manufacturers.

If you have documentation on the cracked skylight (photos) call them back and get an email address to send pictures.

If not, and you haven't reported it to your selling dealer to try to fight for you, then yes, it is on you.

 

[lorend]

OP again: Just got off the phone with GD Customer Service and as I expected, they take no responsibility for "seal maintenance" after 90 days of purchase. They consider it the owners responsibility to fix any external water intrusion occurrence whether is is due to their negligence or not after 90 days. So if there are any new owners reading this, BEWARE and watch your trailer closely! There is no comparison between the automobile industry and the RV manufacturers.

We just went thru the problems of a soft spot on the roof. NOBODY would do anything unless it was due to tree limb damage or a collision. A mobile tech took pictures and pointed out the very small holes created by a limb. Insurance then kicked in and were very quick to get things taken care of. We ended up doing the FlexArmor spray on roof and feel a lot better about the strength of the roof now. We had it done in Pasco, just a couple hours from you. We were very pleased with the service and the job that they did. And it is also cheaper than putting on another membrane roof.

 

[John1953]

Cracked Skylight from day one (purchased Imagine 2970 19 Aug 2023

If you have documentation on the cracked skylight (photos) call them back and get an email address to send pictures.

If not, and you haven't reported it to your selling dealer to try to fight for you, then yes, it is on you.

I reported it to service manager and all i can say is ignorance is bliss. Sealed 5 cracks with silicone as temp fix until I can get replaced.

 

[Hoopy Frood]

Using silicone on an RV roof, or almost anywhere on an RV, is not such a good idea. It's almost impossible to get anything to seal again after the silicone is removed, without an intensive cleanup.

 

[John1953]

Silicone Use

Using silicone on an RV roof, or almost anywhere on an RV, is not such a good idea. It's almost impossible to get anything to seal again after the silicone is removed, without an intensive cleanup.

Understand completely. I only applied the silicone to the cracks on the transparent, plastic cover. Nothing touched the roof membrane but did touch the the self leveling lap sealant inside edge used to seal the sky light. Service manager agreed this was best temp solution as water leaks were fairly bad. The fix will be to completely replace the sky light and reseal with new lap sealant which I will most likely do myself due to distance to dealer and push back when I called them about the problem.
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[Hoopy Frood]

Sounds like a carefully thought out solution. Nicely done.