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Old 07-27-2014, 12:22 PM   #1
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Thor Owners Club
Ford Super Duty Owner
Join Date: Jul 2011
Posts: 2,881
Water Intrusion Problems Late Model Hurricane

Something for current and future Hurricane owners and probably most of the rigs with the rotocast compartments. Had a ripple in the fiberglass under the door for the generator so I knew I had a bit of delamination but didn't know just how much. The repairs are not hard considering the area is below the coach floor line but still pretty bad. After removing the lower edging and storage compartment doors found just about all the backing plywood from about the middle of the storage compartments down was wet rotted. As best I can figure the storage doors frames had little if any sealant and any water that leaked in was trapped by the lower edging.




My fix, that seems to be setting up pretty good, is to fill the 1/8" or so void that was wood with Great Stuff foam. I'm clamping either a cut sheet of ply or a board across a portion of the fiberglass and then fill the void with the foam. The foam expands and fills the space but the clamped wood does not allow the foam to bow the fiberglass.





Completed half the work yesterday before it started raining.



The paint stir stick is to set up about the same gap as back plywood for the foam to fill with the wood framing in place. The foam stiffened up pretty good over night. All I need to do is trim the excess and properly seal the compartment doors. The foam has a bit of resistance to moisture so with a bit of luck this should be a permanent fix.
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