Roof rivets not holding

[Robi.1014]

The aluminum roof panel (just above the entry door) started separating from the rivets...creating a "gull wing" opening just behind the front cap. I did an on-site repair (to regain water tightness) at the RV park using drywall screws. During the repair, I noted that the rivets were not securing this roof panel through holes in the aluminum, but rather through half-moon-shaped cutouts. So it is clear that this seam would pop open eventually.

So just wondering:
Who has observed how these panels are secured at the factory? Was the aluminum panel pre-shaped before installation?...I think not because my panel REALLY WANTED to go straight out!! Also, how common is this failure?

[LeeB]

I have a friend who has a 05 Endeavor and I believe they had the same problem. I'll shoot them a e-mail and try and get more information for you. I know they got it fixed. But who paid? I am not sure..

[R&J]

Other have had roof pop rivet brake off
Roof pulled away from sidewall by slidetopper?

[LeeB]

I talked to my friend via e-mail and they had to pay for the repairs themselves...

[Robi.1014]

Thanks all. I regret to hear the extent of "our" problem.

Still interested though:
How did Monaco attach these roof panels originally?....meaning: were they shaped first (with the curve?) or ???

What astounds me is the force that my popped panel is exerting on the rivets...AND....that my rivets don't have a full bite of the metal that they are to hold down.

[ronshultz1]

If understand your situation properly it is the rounded curve material that joins the roof to the sidewall structure. If so, yes that is a pre-shaped piece installed at the factory.

[dougahlers]

I too have roof rivets popping loose. The threads I have read are using rivets and or screws to repair this problem. I was able to remove a couple of the broken rivets and identify their length to be 1 inch after they were expanded. They are 3/16" in diameter. The rivets penetrated the structural framework of the RV. I have found the rivets to be very soft aluminum and very easy to shear the head off. I am using #12 self drillingtapping screws to replace the broken rivets. I am also replacing a couple of rivets past the broken ones to make sure any stressed rivets are replaced.

[Robi.1014]

Doug,
Did your failed rivets pass through the metal some distance from the edge of the aluminum panel (1/4" or so)? For me, not only did the rivets fail, but the rivets only "nicked" the edge of the aluminum that they were supposed to hold.

[dougahlers]

Robi,
I examined the breaking rivets and holes that the broken rivets came from and determined that the rivets fastened the roof cap and siding to the framework. I used a homemade bent wire tool to feel inside the holes. I could feel the framework behind the siding and I could also feel the opposite side of the framework. The broken rivet that I removed measured 1" long, which gave me an idea of what to feel for. I couldn't believe how soft the aluminum rivets are that I removed. I too felt the pressure from the aluminum roof pushing away from the siding and framework as if the aluminum roof panels wanted to straighten out. On my coach (2004 Beaver Santiam PST) the #12 1 1/4' self tapping screws pulled all pieces together and fastened to the framework nicely in the original rivet holes. I also added some additional screws, where there was in my opinion, too much distance between rivets. I took my time and used a 1/4 inch drive ratchet to install the screws so I could feel the progress of the screws. Worked well. I have the road side of the coach completed and now I need to do the the other side. Really doesnot take that much time to do and screws and caulking are inexpensive. As long as you take your time and use care in removing the plastic cap covering the aluminum rail, the job can be done without damaging the paint.

[Rex]

Doug, not to rain on your parade, but hope you used stainless steel screws. Monaco used screws on my coach and they rusted and caused roof to sidewall separation. I installed aluminum rivets to fix the problem. Could not find stainless steel screws that were strong enough where I live.

[Oh-one]

I had the same problem and did a small area repair, however the separation continued in another area. End result was a total replacement of the monaco inferior rivets with stainless self tapping screws and replacement of the cover cap over the screws and a repaint . Two years later the repair is doing great. It is sad that such a poor system was used to cut cost and put the owners up for later repairs. Just another Kay Toolson Gotcha!