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Old 10-04-2015, 08:09 AM   #1
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Roof cut - new 5th wheel

So today I found a roof penetration on a 5-month old RV. I know it wasn't there during PDI and I'm typically up on the roof every 1-2 months.

It was cut by the AC frame edge, but the AC frame edge is 3/8" above the surface of the roof. The AC is attached well and doesn't move around.

I'm thinking that I've got roof swell on the membrane while traveling...
Any opinions?

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Old 10-04-2015, 08:33 AM   #2
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Hell, I can see it is clearly cut and is cut the same shape as A/C frame. Looks wrinkled also. I would guess it was not taut when it was put down and yes it billowed with wind traveling over it and sucked it up to the frame and hence was cut.
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Old 10-04-2015, 08:33 AM   #3
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WOW! That's nasty!
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Old 10-04-2015, 08:38 AM   #4
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The bonding may have seperated and is pushing the membrane up . Under warrenty take it in before any water gets under it. I would temp patch if it is going to take a while to get it in.
When they are done don't leave the shop till you go up and look. JMHO
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Old 10-04-2015, 08:46 AM   #5
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What happens in a case like that? Are you obligated to accept a repair on a new roof?
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Old 10-04-2015, 05:49 PM   #6
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I have no idea. Most of the feedback that I read on Keystone roof warranties indicates that they defer it to the manufacturer of the roof material (TPO?) or exclude is as lack of maintenance.

I think it's TPO as it has texture.

The Keystone (Thor) warranty also says that roof cosmetic and installation issues are excluded. I assume that's cosmetic issues related to installation, but not sure.

I should probably start with the roof manufacturer and let them indicate that it was an installation issue before I try to take it with Keystone.


It's definitely billowing. I put a camera up there and here's what it saw:

https://youtu.be/HQet_grFELY



Two questions:
1) What's the appropriate repair?
2) As the Carbon has a flat roof, it's always going to be subject to low pressure and turbulance. I wonder if there is a sunroof style spoiler you can get for RVs to help with that?
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Old 10-04-2015, 06:04 PM   #7
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Not sure they can blame that one on lack of maintenance or bad roof material. It's definitely lacking adhesive under that whole section, allowing the billowing. Keystone should cover their workmanship issue IMHO.
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Old 10-05-2015, 02:12 PM   #8
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Thanks.. I've found a number of other Keystone owners having the same issues - most 2014 and 2015. The issue eventually gets bad enough to pull the roof out of the front seal/cap.
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Old 10-05-2015, 02:13 PM   #9
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Another video of the same issue that I found:
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Old 10-05-2015, 02:16 PM   #10
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I agree, nothing you could have done to cause it. Keystone needs to fix that.
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Old 10-05-2015, 03:05 PM   #11
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Anyone know what the appropriate repair is here? I'm reading that Alpha doesn't like re-glue of previous material and needs to have the roof material replaced... But I'm looking for documentation (I've called Alpha).

Note 100% sure I trust my dealer to do it.. Or any dealer for that matter that doesn't specialize.
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Old 10-05-2015, 03:50 PM   #12
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Not sure what Alpha is. We had a tear from a tree branch on our Montana, and I brought it to a dealer, and they cut the tear out, and put a nice patch on it, and it worked great. I had it covered with gorilla (duct tape) waiting to get it repaired for probably 2 months. Never leaked. Went through a bunch of rain, and snow like that until I could get it properly repaired.
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Old 10-05-2015, 07:22 PM   #13
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Alpha Systems is the manufacturer of the TPO material that's on the roof. Part of the RV warranty is a 10+ year warranty of that material, provided it was installed and maintained correctly.

I'd have no issue with a patch on a puncture, but I do have an issue with a patch on a roof of a "new" RV - especially if it's a factory defect.

I've got it in covered storage to keep any rain out. Clearly it can't travel like that...

I was told that the Montana forums has some background on similar issues and associated repairs.
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Old 10-06-2015, 05:58 AM   #14
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In my opinion, I think Keystone should step up and make the repair under warranty. If I were you, I would still put a temp patch on it until it gets resolved. Have you brought it to a dealer yet? I'd be waiting at the service departments front door waiting for them to open.
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