We Have Rebuilt our Pop Up Roof But Need Suggestions for Materials

[DutchmanPU]

We have a 1996 Dutchmen Pop Up camper which had a rotted roof. My husband rebuilt the roof from scratching welding aluminum to create a sturdy and light frame. We are coming in the homestretch. The only thing remaining is to fill the seams and cover the roof. I thought I would post here for some suggestions.

This a photo of the camper being taken apart.


This is a photo of the roof being used as a template.


This is the rebuilt roof using an aluminum frame my husband designed. He thought this would be much sturdier than using wood.


Here is the inside of the roof with the air conditioner hole just cut out. (He added an additional light over the counter tops. It came with one interior light over the sink so he added an additional light.)


Here is the outside of the roof.


OK, we need assistance with this:

1) These are the seams that are left open at the ends of the camper.


These seams need to be filled in and then covered with some kind of material.
Here is a close-up.


This is what Dutchman used to fill in those corners. It is an accordion-style foam strip that was glued to the top of the vinyl top. (This vinyl sheeting is not reusable as it has holes in it and could not be removed in one piece.)


Here is an up-close photo of that foam stripping.


Does anyone have any suggestions as to what product or material we can use to round these seams out?

And the second question…does anyone have a suggestion as to what can be used to cover this camper top? Aluminum is too expensive. We would have to go to an expert to have vinyl or fiberglass put on the camper and since this was rebuilt on a budget, this would not be an option. Any other ideas?

Thanks,

Jan

[Ottawa]

Not an expert in this, but because of the low height of the unit, I would believe that you should use some thing that is some what hard, as the roof is more likely to have stuff put on it etc. This would rule out an EDPM type roof, which is fine for a trailer or motorhome, which because of their height are less prone to some one putting something on it or carelessly climbing on it.

["007"]

Here is a thread that maybe of interest to you.
Here is another to show you how.