20.64-1 Roof Construction

[Snowman]

Hi All,
I have been reading the forum for the last 3 months (while waiting for our van to be built) and it's a fantastic source of information and banter. Now we are owners ourselves I thought that it was time to get out of the closet and get involved.
We have just picked up our first van from Caravanland in WA, a 20.64-1 Outback. The original plan was a 17.56-2 but once I took the big boss down to the showroom the backside out of the budget. In order to get the green light I was also directed to add the annex, external shower, gas bayonet, extended drawbar, washing machine. TV accessories, additional outlets, fold down table and leather lounge. We have 3 kids so the layout with the bunks and separate shower and toilet really suits us.

I have spent the last couple of days getting used to the operation of everything, seasoning the canvas, polishing the duco, and shopping for all those bits and pieces needed to kit out the van and start enjoying more holidays.

When I was polishing it today I was up on the ladder inspecting the roof and I couldn't believe how rough the installation was. The roof is up and down like a brides nighty with water pooling under the A/C unit and along the edges. It looks like the fiberglass has just been slapped on and has warps and bubbles in it and it certainly doesn't look like a Tradesman finish. I am a bit concerned that once the sealant starts to deteriorate the roof will start leaking and it will also start to collect excessive amounts of dirt and dust in the pooled areas. I know that when you are building a house you design sufficient fall and run-off so you don't get any pooling (especially around the areas where you are relying on sealants).

I was wondering if anybody else's roof is like this and if this is acceptable workmanship in your collective opinions?

Thanks in advance for you opinions and advice.

Snowman

 

[bigcol]

I hate to say it, but, I think you may just have a problem

who was the sales man at Caravanland? - maybe give them a ring
Caravanland does not do warranty work for the Jayco's they sell, you would need to take it to a repairer to get sorted

if you have no joy with Caravanland, give Jayco Melb. a call, and explain to them
hopefully the piccies you have also have the date stamp on them
- for evidence that it was like that when you got it, not "wear and tear" from 6 months waiting for your warranty booking

that is a real bugga in my humble opinion

 

[Dobbie]

Yep.

Looks like a problem to me....first stop would be to contact the dealership with photos and questions and get them to inspect it, report on it and deal with Jayco direct.

They can then organise the repair (or whatever) ....it's an issue for the dealership to handle, imho.

It's possibly easier for them to organise a replacement roof.....but there may be a simpler solution....whatever, I'd be getting back to the dealer pronto.

Good luck with it....and :welcome:

 

[Drover]

I thought it was rain on the roof at first, if thars a fibreglas roof then get onto the dealer asap, that is a big fault.

 

[Macca_75]

If the bubbles are rain, then the warping is exactly like mine - very poor but I just thought it was normal. I epxected it to the straight much like the walls and was very disappointed with the roof.

Of course if they are actually bubbles and not water then yours is worse than mine.

Please keep us up to date with what your dealer says. My van is going in on Tuesday for it's first service so I might mention it anyway.

 

[Dobbie]

I assumed it wasn't beads of moisture.....but, if yours is close to looking like that, I'd certainly get them to look at it.

Will be interested to hear of the diagnosis.....and the prognosis.

Good luck to both of you.

 

[Base23]

looks like water sitting on the roof but the warping looks the same as the roof on my jayco Basestation and I was told it is normal.

 

[Zimbo]

Ours is much the same - I have to say I was also a bit taken back when I saw how level the roof top was however I does not leak that I know of so figured this was just a Jayco thing - our van sleeps under cover so never had reason to check it out up top until she got a birthday wash - first couple of washes I lazily just used our telescopic deck broom. These Jayco's are also pretty scary once you inspect the undercarriage however that said ours has been great given the price tag vs. other brands that sure we'd love to have but do not fit the budget

 

[Drover]

So is it a hard fibreglass/timber roof like the walls, moulded fibreglass/plastic or a flat tin roof ???????

 

[Dogger]

Great looking van! I have the same on mine at first I looked and said wtf? I was pretty annoyed about it and thougth I hope I don't have roof issues. I was searching and found this video on how they slap 'me together!
Check it out (hope the link works)

 

[twscoot]

I think you'll find the roof is a single sheet of rolled fibreglass literally sitting on top of a frame, sealed around the edges. It's not that dissimilar to many I've seen. Including my own. The large pooling of water is perhaps excessive.

 

[Duncanblake36]

That looks like some one has walked all over the roof as where those dips are are between the metal frame.

Get it sorted as that will cause you so much trouble later on - especially with the pooling water.

Sorry to say but if that was me I would ask for a new roof.

 

[Smash]

This is normal they are classed a floating roof so they can move and flex on the roof,it is only fixed by the sides and where the hatches and aircon are so it can move in the different weathers conditions.

 

[Drover]

So its just a thin sheet like a tin roof, then the buckled look with puddles is normal......

 

[bigcol]

So its just a thin sheet like a tin roof, then the buckled look with puddles is normal......

sounds about right........................?

 

[Snowman]

Thanks everybody for your opinions and great information! It's all very much appreciated.

Just to clarify that it is beads of water on the roof and it is more the buckling and low spots that were concerning me.
It look's like quite a few punters are in the same boat and have roofs that look similar and going by some of the descriptions on how they actually install the roof it makes a bit more sense.
Having said that it still doesn't sit too comfortably with me when you are relying on the sealant to maintain it's integrity over many years of weather and movement. I guess that just emphasizes the importance of storing your van undercover and periodically checking the condition of your sealant.

I contacted the dealer Service Manager and his response is below:
"Hi,
Thank you for your email, looking at the photo’s the roof is normal all will have high & low points
You can if you wish lower (or Raise ) the jockey wheel to allow water to run off while parked up but I can assure you that there is nothing wrong.
I have noted your concerns & I will get the service team to inspect it when it comes in for its first service."

I think that I will head down to the dealer with my ladder and check out a few of the other vans for comparison.

Snowman

 

[Dean Anderson]

I was talking to someone the other day about hail storms and damage to fibreglass v aluminium vans.... I know it doesn't look pretty with the warping... but if the roof had to be replaced its better off not being glued down to the ply underneath. Contraction/Expansion of the fibreglass is only about 2mm over 6m with a 45 degree temperature change so isn't really an issue.

Are the highs and lows solid or do they flex up and down easily??? If its solid I suppose some of the insulation may be between the ply and timber roofing frame. It would be interesting if it changes shape over time.

I wonder what Jaycos time recommendation for changing all silicon sealant for the roof is???

If Jayco reads this.....Please buy the guy doing the insulation a serrated bread knife for cutting the batts..that Stanley knife is hopeless.

 

[Drover]

When I was van shopping for The Tardis's replacement I checked the roof on heaps of vans, tin roof it is the norm for it to have dips and hollows, puddles in the rain, Big Mal has some small lakes in a downpour and having a slightly high bubble ensures water run off, so have a look at other sheeted roofs and I think you will be hard pressed to find any with no bumps other than the hard roof types.
That is probably why when inspecting van roofs you will notice the silastic around the edge is troweled on to allow for expansion and contraction.

Not a good look by any means.

 

[Bellbirdweb]

My roof on the 21.64-1 looks exactly the same.

Part of the service check list that my service agent uses has a specific check for roof sealant with a yes/no for remove and replace, so I think it's something that becomes a regular check with this type of roof construction.

Out of interest I'm regularly up on my roof as it's the only way I can get the cover on, and it seems plenty strong enough up there.

 

[Crusty181]

@Smash is spot on, only fixing points are edges and penetrations. The less evenly spaced penetration the more wonky. The only Jayco with a sold framed roof is the Silverline. All the rest, including pop top are exactly as described by @Smash .... and from the "Jayco design" perspective if your roof isn't like that, your the odd one out.

If you ever camp in a caravan park on a slope where you can see over the caravan park, you can pick all the Jaycos just from the roofs.