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Old 10-14-2014, 01:31 PM   #1
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Fiberglass Roof

I have a 2011 Thor Challenger and have found soft spots on the fiberglass roof. I found one, which is the bigger spot, by stepping on it while cleaning the roof. It was like a crunching sound and feel. Can someone please tell me if you have experienced this and what it could be caused from? Can it be repaired, or what I can do without replacing the roof?

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Old 10-14-2014, 03:01 PM   #2
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Glad you're aboard. IMO May be dry rot caused from a leak. Best of luck on a solution. Enjoy your adventures and be safe.

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Old 10-14-2014, 05:14 PM   #3
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Hi Frank! Welcome to IRV2! It's great to have you join the gang!

Flexibility in a fiberglass roof is not uncommon, though I'm not sure about your brand. I would check with the manufacturer tech support on this.

Good luck, happy trails, and God bless!
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Old 10-14-2014, 11:58 PM   #4
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Good luck with a solution.
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Old 10-15-2014, 12:40 PM   #5
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Are you sure the roof is fiberglass?
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Old 10-15-2014, 04:03 PM   #6
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Thor does not offer a fiberglass roof on the challenger. It is a tpo roof the crunching is the insulation between the metal joists cracking
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Old 10-16-2014, 06:23 PM   #7
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Old 10-17-2014, 09:53 AM   #8
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Originally Posted by davdamon View Post
Thor does not offer a fiberglass roof on the challenger. It is a tpo roof the crunching is the insulation between the metal joists cracking
I spoke to a representative with Thor RV Company and did find out it is a Dicor rubber roof. The crunch sound is most likely the quarter inch plywood the rubber sheeting is attached to. We have no tears in roof, still looks new so don't think it is a water leak. Probably weight issues from walking on weak plywood??? Was told to get foam sheet to lay on roof to distribute weight when walking up there. Thanks for your responses!
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Old 10-17-2014, 12:09 PM   #9
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The EPDM rubber is laid over plywood and glued to it, so there should not be any crunching sounds. Assuming you weigh less than 300 lbs, that is. If it is weak enough to make crunching noises, I suspect you already have some water damage underneath. The roof material can be fine, but water can still enter in dozens of places, along seams and around vent, skylight and a/c openings, etc.

In the short term, you can cut some 1x1 ft plywood squares to use like snowshoes when you have to walk on the roof. Even 1/4" plywood is enough to spread the load.

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