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msimmons · 07-07-2013, 03:36 PM

The 4 corners are tight (too tight, broke one but that is a diff story), with about a 1/8" space between roof top and the bottom of the ac condenser unit.

However, in the area between the bolts, there is about a 3/8-1/2" space between the roof top and the bottom of the ac condenser unit... and we are taking in water.

The "metal plate" that touches the ceiling is made of a very flexible thin metal (probably aluminum) so it doesn't provide even compression...

Any suggestions?

(I also apparently have a garbage torque wrench as well because even set at 20 lbs (the instructions say to torque it to 40lbs) it never gave an indication that I was at torque. While trying to tighten the bolts more in attempt to stop the water... one snapped.)

jnp_macklin · 07-08-2013, 11:33 AM

From my understanding, usually there is supposed to be a black/gray "closed-foam" open square gasket that surrounds the hole in the roof that the AC fits over that seals against the roof of the RV. is it possible that gasket has failed/been lost/misplaced/thrown out? I believe that gasket is about the thickness of the gap you are reporting in your current situation.

Like this...... RV Roof Air Conditioner Gasket Kit - PPL Motor Homes

msimmons · 07-08-2013, 12:26 PM

Sorry, I meant the "gap" is the foam gasket. It is compressed to 1/8" in the corners, but hardly compressed at all (it is 1/2" right out of the box) in the space between the corners.

BFlinn181 · 07-08-2013, 12:46 PM

Sometimes the cut in the roof is not adequately framed. Are the edges of the roof opening flat and supported by metal or wood framing? The top and bottom of the opening should be filled with a metal or wood square that prevents collapse of the roof or ceiling when bolting it tight. Only the gasket should compress, not the roof or ceiling. I think you'll need to remove the A/C, build a proper frame into the opening, then reinstall. You need to give it proper support to prevent future leaks, rot, or rusting. Don't be tempted to fill the gap with more foam or caulk, do it correctly or have it done.

msimmons · 07-08-2013, 01:13 PM

The previous AC's 'lower unit' had a steel plate, so the pressure was applied evenly. This AC's 'lower unit' is made of aluminum so I believe it is compressing the ceiling in those corners.

I'll see if adding some steel between the aluminum and the ceiling will help.

(I'm currently stalled out while waiting for some bolts to arrive. I was unable to find any locally so had to order them.)

msimmons · 07-11-2013, 11:13 AM

wow... so it turns out, it wasn't the seal at all. The roof is sagging around the ac, causing a puddle, that is deep enough for water to come in the holes designed to let condensation out...

If it was the seal, that puddle wouldn't be there