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Old 08-19-2012, 12:34 AM   #1
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Roof repair question

Just back from the first week shake down cruise and had lots of rain. NO leaks (due to the reseal I did with Eturnabond tape) BUT I noticed that the "depression" on the roof around the A/C unit (noticed this on the prebuy) collects a water pool (surprise, surprise). Knew I was going to have to approach this issue at some time. The roof was flat when it was made and I doubt it was designed, at that time, to support a big A/C unit for so many years. Anyway my idea is to run 1 1/2 inch heavy wall square tubing crossways in front and behind the a/c unit from side to side and use a 1/2 inch thick bar inside the box on the ceiling fore and aft on each side of the a/c unit, with bolts (well sealed), up through the roof into the 1 1/2" tubing, to pull the 1/2" bar up and so bring the roof up at the same time. By using angle iron along the roof edges on top (fore and aft running) under the square tubing, the tubing will be @ 1/8 inch above the original roof line thus allowing me to pull the roof up to level and spread the load along the top edge, fore and aft, for better support.

Anyone ever done anything like this?
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Old 08-19-2012, 07:20 AM   #2
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I done a similar fix in many pop ups they were known to sag over time, what your doing is the same thing basically, usually when a roof sags like that it a structural beam that has come loose or rusted out and come loose causing a drop is there anything in that area or on the sides that has moved lower, there again over the years and the weight of the A/C bouncing up and down and just sitting there would cause the bowl effect.

The opening of the A/C hole has tubing and it is connected to the beams that go side to side sometimes there doubled to prevent this but sometime there single to save $$$

The way the pop ups are done is the same ides you have with the tubing but it's 1/8 inch size which will hold a lot but 1/4 will be better for the span there is a plate that wraps the tubing on each end bolts go through the plate and through the roof to a flat plate on the roof tighten it all up and seal plate and nuts
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Old 08-19-2012, 09:43 AM   #3
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With the weight of the a/c unit on that span it would have to be a well engineered design to support it. I don't think any manufactuer would put the time and money ($$$$) into this if the a/c unit "looked" like it would stay in place as it went out the yard. I haven't taken the a/c unit off yet buit the roof is solid both inside and out with only small signs of water stains so I don't suspect the ceiling is rotted out. No external signs of it anyway. I think the 2" square wood beams just have not been strong enough over the years to support the a/c. 8' span on just 2X2s with a luan skin inside and thin aluminum on top. No way it will support all that weight without sagging for 35 years. When it was new, sure, 35 years later and bouncing along the hiway with 2 or 3 Gs of load with every bump-nope.
The fore and aft inside bars will go across 4 lateral 2X2 roof "joists" so I'll be lifting basically in 4 structural places on either side of the a/c unit and not just on the luan ceiling plywood.
When all is said and done I'll just need to find a good way to repaint or wallpaper(?) the inside ceiling to hide the few water stains. Luckly the PO had a cover on it for most of its storage life.
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Old 08-19-2012, 06:34 PM   #4
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Sounds like a good game plan I think it will work keep us posted and take a photo to share the fix
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Old 08-20-2012, 12:46 AM   #5
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It'll be a couple of weeks but I'll keep it posted
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