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Old 03-21-2016, 10:18 AM   #1
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Exclamation Hello, Newby with Bunk over Cab Floor Separation, Please Help, San Antonio

Hello, sorry I am introducing myself with a help request. I bought a 2002 Four winds 32 footer about a year ago. As an Air Force member we move every couple of years and used this last move as my excuse to buy the RV I have always wanted.

I bet the solution is already here and I can't find the solution because I don't know the proper terminology to search.

I got a great deal on the RV because of known water damage over the cab. After re-sealing any cracked caulking to fix the leaks the first thing I did was to get up in the sleeper section over the cab and start pulling everything out that was wet or rotted. I ended up pulling out most of the floor wood, and a little bit of driver side wall. Any gaps in white foam insulation I filled with spray foam, them I installed a new 8 foot wide plywood floor, I used liquid nails to attach it to the foam below.

This repair seemed to work great until our spring break trip to Mustang Island TX last week. At a gas stop I noticed the a half inch open gap between the exterior side wall and base of the sleeper cab.

Please help me with what that metal trim rail is called, I think it may be a T rail. It is still firmly attached to the Floor fiberglass but the side fiberglass is totally separated. I already replaced all the rotten wood on the inside but don't know how to reattach the outside.

My temp fix was to run a bolt through the outside metal rail into my new wood floor, this kind of worked but it pulled the floor down a quarter inch. I filled this with caulking to finish the trip. But the floor does not seem as strong and I have 2 kids that sleep and wrestle up there.

It seems that wall is designed to carry the load weight of the floor so I need to figure out how to attach the two. Any metal I find seems to be thin aluminum that I don't think would carry a load. And first attempts with self tapping screws just strip out the hole under any load.

Ideas are to find some aluminum 90 degree angle iron to replace the existing trim the put a million screws through the fiberglass to distribute the load.

Another idea it to make a fiberglass cap in hope of sticking the exterior wall and roof together, but I don't know if it will hold.

I'm in a time crunch to get it back to the storage place because the HOA has already gave me notice to move it, and I want to prevent future damage.

Please point me in the right direction, if you know any good help in the San Antonio area please let me know.

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Old 03-21-2016, 01:07 PM   #2
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Welcome to IRV2! We're sure glad you joined us!

Congrats on the new rig! Sorry I can't offer advice on your problem! Keep her between the ditches!

Good luck, happy trails, and God bless!

Joe & Annette

2002 Monaco Windsor 40PBT, 2013 Honda CRV AWD
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Old 03-21-2016, 02:39 PM   #3
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Glad to have you here with us.

Sorry to hear that you are having problems. Have you tried contacting Thor directly? They may have some ideas for you. Motor Home Specialist LP in Alvarado is a Thor dealer (800) 335-6054. It is a long haul from where you are (approx 240 mi.). Call them first. There are a couple of Camping Worlds nearer to you, but I don't care for CW service.

Hope this helps you.
Tony & Ruth........... FMCA#F416727
Newmar Dutch Star 4320, Spartan MM Chassis, Cat C9, Jeep Grand Cherokee,with Hemi, hooked up with a Blue Ox Aventa LX, and Brake Buddy.
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Old 03-21-2016, 04:02 PM   #4
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Old 03-21-2016, 04:08 PM   #5
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Hi, welcome to IRV2. Hope you get the answers soon. Safe travels and Thank You for your service.
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Old 03-22-2016, 06:44 AM   #6
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Old 03-22-2016, 01:18 PM   #7
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Welcome to the forum and thank you for your service.

Go to "Vintage RV's" Someone there should be able to help you. I would suggest posting a picture of what you are talking about. Pictures always help. Lot of people there who have torn apart their RVs and they have had to order a lot of parts.

Good luck with your rig. You should be able to get it figured out there. There is also a "Military" forum here for you military types.
Love the sunshine and warmer weather!
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Old 03-22-2016, 01:32 PM   #8
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some you tube video on over cab repair


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Old 03-23-2016, 10:23 AM   #9
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Thanks everyone for all the quick advice. I appreciate the links and places to search. The Thor team is trying to find me a parts diagram to help me with how it is constructed. The videos helped, I intend to put together a repair slide show as I work.

I have hired a person from Xpress RV in San Antonio to come out and diagnose the repair and give me an estimate. It's $85, but I have a whole list of questions that would be much easier to explain in person, so I think its worth it.

They claim to have 20 years experience and have done this repair before.

I will keep you updated

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