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Jayco Sportster 8ft - Renovation


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#191 Manfred65

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Posted 10 April 2021 - 12:43 AM

Hi Guy,

 

you are welcome with all  question you are going to ask me or Cory.

 

I covered the roof with tintable Raptor Liner and a little white colour in it. This is the best solution in my opinion.

 

The old roof was rebuilt but i never brought it to it´s old shape and i always had two leaking spots. Two many screw holes due to the aluminium profile that runs north south on the roof. The roof is built from two sheets of aluminium and the line in the middle where they are connected is the weak point on the Jayco.

 

 

We are going to replace the entire roof this spring. 

 

I am importing Bundutec USA Campers to Germany and got some of the aluminium profiles they use for their roof + all the smaller parts.

I think that is my dealer benefit ;-)

 

Then i ordered a 1" fiberglass/foam sandwich with a reinforcement where the hanging closet is and pre-cut channels for the wiring.

Not a cheap solution but i needed another panel to close the back wall of a box truck that we convert to a RV so i saved 1x shipping cost.

 

The L-Profils at the corners are not an easy fix. I needed the wide  profiles to cover dozens of screw holes from the previous owners. Smaller profiles must work better because they are available of thinner material. It was a hard job to get them on the corners, glue and fix them.

 

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2000 Ford F-250 SuperDuty SC LB 7.3 Lariat
1992 Jayco Sportster 8ft Popup

http://www.wanderthe...8ft-renovation/

BundutecUSA, TravelLite and Palomino TruckCamper Sales in Germany and Europe

 


#192 corybrown50

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Posted 10 April 2021 - 12:53 AM

Hey Guy,

Ask any questions for sure. I wish I had taken my roof off to rebuild instead of trying to do it from the inside. It definitely didn't come out well and with the minimal difference in effort it would be a much better choice.
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#193 corybrown50

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Posted 10 April 2021 - 01:10 AM

If you like, here is the link to my rebuild as well.

https://www.wanderth...tschland/page-3
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#194 HoppyToGoWandering

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Posted 10 April 2021 - 04:33 AM

Awesome! Thanks Manfred & Cory! And yes, I am going to put in pink or blue foam board when it comes to that "lovely" task! Ha ha ha! Thanks for the lead on the Raptor Liner. I've used Harbor Freight bed liner to varying degrees of success. Guess it matters on the application. But there is zero chance that I'm putting black bed liner on the top of a camper. No! Definitely not for Southern Idaho, Eastern Oregon, of Eastern Washington. Might as well go down to Death Valley for the summer, might even be cooler if I did that! :D  :D  :D

 

I'll keep in touch!


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#195 corybrown50

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Posted 10 April 2021 - 06:19 PM

I can't remember how much weight I lost after removing the soaked insulation, but it was a lot. The pink is closed cell if I remember correctly. Not sure about blue.

Hopefully you have some buddies to help remove the top and a garage or covered area to work. It is definitely my biggest regret on rebuilding. May still do it if a leak forms. Having a buddy in the industry with all the right sealants for the different areas was a huge bonus.

Edited by corybrown50, 10 April 2021 - 06:21 PM.

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#196 alan_h

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Posted 31 August 2021 - 05:15 PM

Hello Again:

 

In your report you noted that Jayco sent you manuals, instructions and other data.  I contacted them and was informed that these were no longer available.  Can you please post them for me to download.

 

Thank you,

alan_h


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#197 corybrown50

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Posted 31 August 2021 - 05:21 PM

If Manfred doesn't have the manual, I actually still have the original from the camper. I will get it and scan it when I have a chance. 

There is a website with it already scanned though

https://www.cunningh...als/1992_tc.pdf


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#198 Manfred65

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Posted 31 August 2021 - 10:16 PM

Hi Cory, 

this is great that you have the manual.

 

Hi Alan,

What Jayco sent me was some drawings of the structure and the roof. Unfortunately i lost the files due to a harddisk crash 3 years ago.

 

But be sure it was no secret in them. If you pull the aluminium outside off you can see everything an it is all self explaining.

My major problem was ( and still is ) the roof. It is 98% sure that these roof are leaking. Most time they keep the water inside, get heavier and heavier and make the rooflift fail. When i tore mine apart it collapsed. We tried to rebuild it without removing it but there have been two spots where i couldn´t find the leaks. Not even with an ultrasound machine that i normally use to find leaks in our shop. I hope i can find the time to rebuild the roof this fall or winter. I have bought a fiberglass/foam sandwich panel with reinforcement where the hanging closet sits. Using this and aluminium profiles from BundutecUSA i hope to rebuild it...i only need to start....

 

We love our Jayco and hope to save it for our future trips.

 

 

Keep on your good work guys.


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2000 Ford F-250 SuperDuty SC LB 7.3 Lariat
1992 Jayco Sportster 8ft Popup

http://www.wanderthe...8ft-renovation/

BundutecUSA, TravelLite and Palomino TruckCamper Sales in Germany and Europe

 





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