Duct Separation

[DancinCampers]

Well, it finally struck. Spent last month down in Louisiana and temps rising to hi 90's, hi humidity and coach temp rising to mid/hi 80's. At first I thought it was the humidity, water pouring out of the unit. But not that lucky.

The seam on the long straight duct inside the cap had opened, tape came undone.

I have posted some pics in the members photo section.

I used my small plastic camping world folding table and a piece of 4 inch swimming noodle to make a temp repair.

My first attempt I used 3 inch foil tape to repair after cleaning. Of course I could only reach about 1/2 of the split from below. This lasted 1 week.

My second attempt I used 5 1/2 inch foil tape. As recommended by RKL2, I removed the taillight. This allowed me to put in some cross pieces & also some along seam higher up.

My tools included backscratcher & BBQ tongs with silicone ends.

As an additional repair, I made a block from 4 inch swimming noodles from WalMart, 2 wide, 2 1/2 deep, 16 3/4 inches long. This is installed between the duct and cap, between 2 aluminum frame members. Held in place by foil tape around the noodles to the back cabin wall.

After our 1100 mile trip to GNR, it is still in place. This helps to keep strain off the tape.

I think the piece of duct is actually ductboard, folded and seamed on one length. If the factory had installed an addition strap 1/2 way up I don't think the seam would have split.

The rest of the system seems ok, I do have some small air leaks around the elbow leaving the unit, but will have to wait till I get home to drier climate, when there won't be any condensation where the leaks are.

[DriVer]

Quote:

Originally Posted by DancinCampers The rest of the system seems ok, I do have some small air leaks around the elbow leaving the unit, but will have to wait till I get home to drier climate, when there won't be any condensation where the leaks are.

DancinCampers, I have an 03 38G and they pulled the rear cap off of mine to fix the duct. This was about 3 years ago .... it's holding!

[Thudman]

Dan:
Here's how I fixed my duct leak

Basement AC Duct Leak

Looks like your repair worked also. Good pix.

Thudman

[charles tuit]

On my 02 Journey at the rear axcess door, to the right side is a sheet metal panel that holds the bumper and lock brackets. This can be removed with 6 sheet metal screws which gives better axcess to the duct. You don't have to lie down to retape.

Charlie Tuit
02 Journey 140,000 miles
XL-7 toad