2720 Roof/Ceiling Repair

Cuzziff · 07-11-2021, 06:57 PM

2003 TM2720

Started to pull back the Band-Aid to understand why I had a small leak coming from just in front of the AC unit and randomly changed to just about above where the front bed starts. Of course it was right down the middle so I started to pull away some of the caulking and trim on the ceiling. Turns out Styrofoam insulation is incredibly spongelike and absorbent. It was no wonder why or after all of the torsion bar adjustments and scratching our heads that we were still not able to open the 2720 without another male around. After flagging certain passerby’s and bringing Olympic powerlifters with on my trips we were able to get the front section open.
This thing is either garbage or I have to repair that ceiling. I cannot very well sell it to somebody knowing that there are hundreds of pounds of water just sitting above their heads. Being that everything works perfectly and the only damage is on the front part of the unit. I know Vennes this morning headfirst.

Shane826 · 07-11-2021, 08:51 PM

You just destroyed that roof panel. Collapse is imminent. The aluminum and foam are all that’s in the roof. Think of it like a unibody car… The shape of the body is what holds the body into that shape.

**wbmiller3** · 07-12-2021, 06:47 AM

"I know Vennes this morning headfirst. " ???

Cuzziff · 07-19-2021, 07:27 PM

Made my way through the front section above the front bed all the way to the cabinet. All rott and mold/mildew. Cabinets are like a sponge, complete loss. If you are questioning whether your TM’s front section is getting heavier each time you open it, it’s probably filling up and completely saturated with water. There is ZERO framing in the ceiling. You would think that styrofoam wouldn’t be absorbent (crab trap markers, temporary coolers full of ice and soft drinks, etc…). Not TM styrofoam. Sent a sample for testing to see if the mold is indeed a bad form. Would explain the sniffles and coughs but we all have athsma so could be unrelated i suppose. Not going to assume. Let the re-FRAMING begin. This thing is gonna be sweet!

Onyrlef · 07-20-2021, 06:34 AM

There are different types of foam, open and closed cell, high and low density. Some types are impervious to moisture, some are not.

**Kidkraz** · 07-20-2021, 10:04 AM

Please post pictures, I'm sure several folks are interested to see what the shells look like.

Shane826 · 07-20-2021, 01:52 PM

I’m very curious what you’re going to use for roof braces. I’ve had a couple ideas but they usually come down to a bowed piece of wood or aluminum needing solid support on the ends to hold its shape. Unless you have access to a gigantic radial bender… I have one idea left, I’m curious what comes to be here.

Cuzziff · 07-21-2021, 09:30 PM

As of now i have been trying to get in touch with Andy in TM Parts to get the new plastic flange covers for the A/C Unit, fan-Tastic vent, and any other new covers like the antenna mount from the interior side. Everything has just kinda dried out and become very brittle. Thanks for the info on the open cell the foam versus the clothes cell the foam Onyrlef!! I have all of the moisture ridden damp foam areas scraped out and debating now whether to make some square foam cuts to salvage what foam is left and has never been introduced to moisture. I suppose a different insulation/foam is out there that is rated highly enough while staying as thin as i need. Rigid Board seems like it would be an option being that the angle isn’t severe enough to cause it to break. My company’s welder is supposed to get back to me on the aluminum options we would have to re support the a/c unit. Going to have to get the framing in the interior complete before i can strip the roof of the years and years of poor repair jobs on the front shell. I will post pics and if anyone has recommendations or Andy’s cell phone #, or the person responsible for poor upkeep on my beautiful, saturated styrofoam free camper…. Please reach out. Cheers and Smile!

**Bill** · 07-22-2021, 05:58 AM

I'm not sure who Andy is. Somehow it is not the name I remember from the parts department. The Trailmanor web site has a phone number for parts and service prominently displayed - have you tried it?

I wonder if some minimally-expanding spray foam might be good as a filler for the empty space? If done right, it would bond to the inner and outer skins, re-establishing the structural strength and rigidity that was originally part of the roof. Obviously, "minimally-expanding" would be of prime importance. You want to fill the void, but don't want to force the skins apart.

I understand your frustration with the situation, and I sympathize with you. But if you are looking for someone to help you, you might remember the old saying about flies-honey-vinegar - or burning your bridges.

Bill

Onyrlef · 07-22-2021, 07:52 AM

Your conundrum will be re-establishing structural integrity while maintaining the somewhat delicate dynamic between the torsion lift system and the shell weight and balance. Not only must you consider raising and lowering, but also lateral motion of the shell ( listing), especially when the torsion bars are between horizontal and vertical on the way up and down. If the shell lists when in the upright position you won't be able to engage the square keeper tubes or at least keep them engaged. Not entirely sure I wouldn't explore replacing the front shell or perhaps inquiring if their plant can't do that kind of repair. Either would entail a trip to the plant, but if you game theory it out....