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Old 08-21-2017, 07:13 PM   #1
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Epoxy needed to repair delaminated cargo doors???

I have a 03 Newmar DSDP. Some of the cargo bay doors were delaminating when I bought it this spring. I thought this would be something I could easily fix myself. The problem I now face is finding the proper epoxy/glue to use. I know how to remove and "clamp" the door after the new glue is applied. I just can't find the "product" to work best for my application. Anyone know what I need for this repair?
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Old 08-21-2017, 07:27 PM   #2
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I have the same issue with my Kountry Star at the bottom of several of my cargo doors. I was going to drill a hole from the backside and inject West Marine epoxy and then clamp. However, I spoke to an RV body guy and he suggested that I just leave them alone. Going into my fourth year of ownership and the delamination, as aggravating as it is, hasn't changed in that time. Would love to know how you make out if you attempt repair.

Any photos of your doors you can post?
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Old 08-21-2017, 08:06 PM   #3
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Spelling will be wrong, but Synchro Flex.....
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Old 08-21-2017, 08:54 PM   #4
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I used a two part epoxy from Home Depot and clamped the door One clamp in the middle and one on each end used two 1x4 about 6 inches longer then the doors. It's a 2004 National RV Sea Breeze
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Old 08-21-2017, 09:01 PM   #5
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WEST SYSTEM Epoxy - Marine Grade Resins & Hardeners
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Old 08-22-2017, 05:53 PM   #6
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Originally Posted by lrsses View Post
I used a two part epoxy from Home Depot and clamped the door One clamp in the middle and one on each end used two 1x4 about 6 inches longer then the doors. It's a 2004 National RV Sea Breeze
How did you apply this epoxy? My delamination is more through the middle of the doors. I think it was caused by heat expansion instead of moisture. Also can you tell the brand name?
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Old 08-22-2017, 06:17 PM   #7
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This good stuff I bought mine on amazon.
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Old 08-22-2017, 06:20 PM   #8
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West systems G flex....best I found. It's made for the vibrations of going down the road and it's waterproof just encase moisture get back in in between reseal.

Here was my project....resealed lamination on all my basement doors. Had extreme water damage over 22 years.
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Broke down each door...replaced wood and styrofoam....reused metal frame and outer skins.
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Pressed luan to insides....then outer skins to luan. Used a roller to apply the west systems G Flex on both sides then weight pressed over night. It was strong enough I could put it on two stands and stand and bounce on it without any give. Very impressive product.
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My pressing method.
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One of the finished doors.
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One side after doors were finished.
I wouldn't use any other product myself.
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Old 08-22-2017, 06:57 PM   #9
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Epoxy needed to repair delaminated cargo doors???

The Newmar doors, if the same as mine, are constructed of a foam that's pressed onto a ABS Plastic or Filon panel. My plan was to carefully open a hole in the foam, which is coated on the backside with some type of hard material, down to the void where the delamination is located. Then inject the resin mixed for a longer work time and then tip and move the door to get better coverage within the void. Once the void is covered well squeeze and clamp until cured. Any excess should come up the hole and actually fill it and harden. This approach requires removal of the door. This, at least, will be my approach unless I find a better way to do it.

Whatever you use needs to be compatible with the foam assuming your doors are like my Newmar doors.
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Old 08-22-2017, 07:21 PM   #10
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I would be careful with some of the 2 part epoxy glues sold at big box stores.
I use Westsystem 105 resin with the appropriate hardener exclusively for a lot of projects, if unsure Westsystem has outstanding telephone support. They are the experts.
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Old 08-22-2017, 08:51 PM   #11
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How did you apply this epoxy? My delamination is more through the middle of the doors. I think it was caused by heat expansion instead of moisture. Also can you tell the brand name?


Most of it was just along the edge of the cargo doors used the two applicator supplied with the epoxy also drill a small hole in the back side of the door again applied with the applicator just use the door as your guide.
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Old 08-23-2017, 07:37 PM   #12
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Originally Posted by sjweave View Post
West systems G flex....best I found. It's made for the vibrations of going down the road and it's waterproof just encase moisture get back in in between reseal.


I wouldn't use any other product myself.
How thick is this material, i.e., will it flow if it is injected into a void or is it thick. Any comparison (water, honey, RTV, etc.)?
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Old 08-23-2017, 08:31 PM   #13
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Great fix SJWeave. My advice is to use Epoxy not Vinylester resin. The latter is more common but epoxy is the strongest as I learnt this building some fiberglass parts on my VANS RV6 kit plane. Epoxy is harder to work with and more expensive.
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Old 08-24-2017, 03:53 AM   #14
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G flex is the thicker of the West Systems epoxy. Not quite the thickness of honey. I used a roller for this repair but it can be injected. I used it for other repairs on the RV and injected with a syringe.
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West's tech department recommended the G flex due to its flexible nature (it's one of the few epoxies you can actual nail or screw into without the epoxy chipping or splintering. It's also waterproof.
I recommend calling them and letting them know what your going to repair and how, their support is second to none.
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