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Old 10-09-2007, 07:33 PM   #1
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Roof Construction

Can someone explain the layers of roof construction of a 2007 Sunline Solaris? I can see how they build it right up until the point where it's insulated. What goes on top of the insulation before the rubber roofing material goes on? (I'm thinking Jon knows the answer to this one for sure, or Kitty or Pat & Cindy since they both ordered an upgrade to a hard roof.)
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Old 10-09-2007, 07:48 PM   #2
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Pam,

You're probably right that Jon, Kitty, and/or Pat & Cindy know the specific answer.

I believe the standard roof has a 1/8" piece of luaun (or plywood) under the one-piece rubber roof. The walk-on roof option I think they increased it to 1/2" plywood.

You can sort of see it on the camper in the background in this picture:


Hope this helps, at least until one of the experts pitch in.
Hutch
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Old 10-09-2007, 08:14 PM   #3
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Hutch,

I believe you pretty much got it right. I have the 1/8" luan with the aluminum roofing. I didn't opt for the walk-on roof, as I'm afraid of heights (IF I got up there, I'd be afraid to get down) The rubber roof material is "glued" to one large sheet of luan, size depended on what model trailer roof it was for, but it was one whole sheet, not pieced.

The walk-on option upgraded the luan to plywood. I don't know what thickness the plywood was, or if the walkon roof was one piece of wood or maybe 4x8' sheets.

I'm sure Jon will know that.
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Old 10-10-2007, 10:46 AM   #4
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Fortunately, I haven't had to experience taking a roof fully apart before, but to the best of my knowledge, everyone has it correct so far. It's the 1/8" luan with rubber on top, all pulled tight at the seams and attached with the metal channel and screws .

Jon
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Old 10-10-2007, 10:58 AM   #5
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Thanks you guys. Some nasty salesman at one time had made the comment that "Sunline uses cardboard as a backer for their rubber roof." I just needed to put that one to rest.
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Old 10-10-2007, 12:26 PM   #6
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I do not want to throw a monkey wrench into this, as I really do not know what was used. During the auction (just about where Hutchís picture is) they had tables set-up the whole length of the tracks for all the hand tools. I went up to the upholstery area upstairs to get a better view through the crowds. Up there they had the biggest roll of thick brown cardboard in a 4 ft diameter by about 10 foot roll. It was the biggest roll of cardboard (not corrugated) I have ever seen, it must have weighed 2 tons. It was about as thick if not thicker than tar paper. I assumed at the time it was either used for patterns or a backing for the flooring. I hope it wasnít used for the roof. I can also assume the roll would have been closer to the gantry they used to install the trusses. It wasnít in a convenient place to where they assembled the roof.
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Old 10-10-2007, 01:20 PM   #7
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Hmmm...guess we need to hear from someone who took the factory tour and was paying attention in the roof construction area. We took our Cub Scout Den about 1991 and I think I was more focused on controlling 8 little 8 year olds than how the Sunlines were being made!
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Old 10-10-2007, 03:00 PM   #8
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Pam,

Maybe you should PM Carl (aka Eclipse) to find out the answer. There's nothing better than hearing if from someone who was there.

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Old 10-10-2007, 03:53 PM   #9
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I got up on a ladder and knocked on the roof. It sure has alot of give to it...more than it would seem like luan would have. Maybe it is a heavy guage cardboard. Maybe it doesn't matter?
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Old 10-10-2007, 04:55 PM   #10
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I'll have to ask my Dad how my '94 was. He was the one to patch the cracks in it from the inside. I never really saw the inside of the roof until the new insulation was in because I helped with the interior panel. Unfortunately, I won't be able to ask him until tomorrow or so when he gets home from the woods.

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Old 10-13-2007, 04:02 PM   #11
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I'm not sure if they put the Cardboard between the plywood and the rubber, but something tells me they might have used it for a barrier/cushion between the two.

It's not like the Cardboard is the only thing on the roof

I know for the roofs that were Walk On Models, they had 1/2" thick Plywood and the Non-Walk On Models I think had the 1/4".

I cant imagine even a salesman thinking that any thickness of cardboard would hold the rubber roof taught against the rafters? Obviously just another salesman talking smack

I'd try and get ahold of Carl, he'd know for sure.

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Old 10-13-2007, 05:55 PM   #12
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I followed everyone's suggestion and here is the reply I received.

What is under the rubber is what we called Bud board, very simular to cardboard, but not really. It was glued to the rubber 24hrs. before they would install it. There is some cases that some units have had plywood decking as a option.
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Old 10-17-2007, 07:46 PM   #13
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Pretty scary in my opinion. Water and cardboard do not mix well.

Has anyone ever heard of someone having their complete roof structure?

Is it even possible since the factory is gone?

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Old 10-18-2007, 06:33 AM   #14
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Quote:
Originally Posted by MikeM
Pretty scary in my opinion. Water and cardboard do not mix well.
Iím not scared or worried at all. Given the track record of Sunline using high quality products and materials in their trailers, Iím sure they used materials on the roof that exceeded what most other manufacturers used.

Plus, they DID NOT use cardboard. It was a processed material, which was glued to the underside of the rubber roof to provide some structural integrity to the rubber.

The rubber and seals is what provides weather protection of the roof. Water is not good for ANY of the materials below the rubber roof. Thatís why itís so important to check the rubber roof and seals regularly and to fix any rips in the rubber or dry/missing seals immediately.

If you would research the materials used be other manufacturers that build trailers without a walk-on roof, I would bet that the materials they use are much more inferior to what Sunline used.

One advantage to a rubber roof over other material is that there are no seams. The other advantage that itís quieter when raining.


Quote:
Originally Posted by MikeM
Has anyone ever heard of someone having their complete roof structure?

Is it even possible since the factory is gone?
Not sure what you mean here. Are you asking if anyone knows of some who has replaced the complete roof?
I donít know anyone personally that has had this done. But most RV repair shops have the capability to replace the roof. There is no proprietary information or secrets to roof replacement, so I would imagine any reputable RV repair facility could do an excellent job.


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