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Old 04-30-2010, 04:05 PM   #1
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How my Pop-Top Leak was Amended

Hi

This is a continuation of a old posting:
Pop-Top Canvas: Mold & Condensation: How to Amend Problem?

I have a 2001 Ford EB 250 with Penthouse Pop-Top.

My issue with my pop-top was that it was leaking due to poorly installed yakama roof-rack by some previous outfit or owner before we bought it, no sealent around any of the blot mounts. I live in the Pacific NW, and when I say rain, I mean rain. During the rain, water was building up within the pop-top's underside. One day when I had inspected and pushed up the pop-top, a waterfall dumped gallons on to the floor.

My neighbor had exactly the same problem with their Jeep. It had a leak and molded, they had to get rid of it because of poorly installed roof-rack.

I took it to Evergreen RV Supply & Service - Shoreline, WA - (206) 542-1183, and they did a great job. They are always backed-up with many RVs, primarily roof repairs, so expect to leave your unit for 6+ weeks. Be sure to bring a tarp and remove all contents (valuables, gear, and stuff) because it will be out in the back stacked next to other RVs waiting for service. Even remove the loose bed boards, because this will make it easier for them to work on the unit and not accidentally stain or lose items.

I had called many RV outfits within the Pacific NW, but many never heard of SportsMobiles. And when I said pop-top, they were thinking the old VW vans.

Evergreen RV completely took off the pop-top and ripped out everything on the underside to expose what was as occurring. It was noted that the original SportsMobile construction of the pop-top was poor.

Evergreen RV completely reconstructed the underside: New boards, panels and insulation. The work took about two weeks after the 5+ weeks to wait to begin work. They did not recommend that they clean the mold stains, because they would still change by the hour.

So, after the repair, we cleaned off the mold stains with Oxyclean and a small space heater\fan set to low. Got 85% of the stains out. We also purchased a de-humidifier.

Evergreen RV's original estimate was $2400 and the final cost was $2800. For us it was a huge expense, but it was worth it and we are pleased with their work. Ask for Jeff, he is the head of the service department and he is very knowledgeable.

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Old 05-01-2010, 10:15 AM   #2
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Re: How my Pop-Top Leak was Amended

Can you elaborate on the "original SportsMobile construction of the pop-top was poor" statement?
What exactly did they find that was considered poor construction?
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Old 09-19-2010, 03:12 PM   #3
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Re: How my Pop-Top Leak was Amended

Sorry for the delay in my response,

After completely removing the pop-top, and removing the ceiling panel, I would have expected a single piece of marine-grade plywood that would have filled the space between the roof top and the ceiling.

Except, what I had found was a decayed haphazard patchwork of non-marine-grade plywood, and the patchwork was not contiguous (i.e., the pieces were not fitting snuggly next to each other) and had gaps of a few inches between the pieces.

Now, in the end, the damage to the roof was caused by whatever outfit (performed previously to our ownership) had improperly installed the roof-rack; i.e. no seals or sealant was applied around the roof-rack mounts.

With the repair, we had a single marine-grade plywood cut to shape and proper installation of the roof rack. So the quality of the pop-top is much superior that the original Sportsmobile construction.
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Old 09-19-2010, 07:02 PM   #4
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Re: How my Pop-Top Leak was Amended

jeff00seattle,

Is there any ventilation between the plywood and the roof? To keep out any condensation.

Woody
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Old 09-20-2010, 07:51 AM   #5
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Re: How my Pop-Top Leak was Amended

The penthouse roof construction is very simple. 1. Plywood strip reinforced fiberglass shell, 2. reflective bubble wrap insulation, 3. a 1/8" non-water proof luan plywood with a white finish on one side.

Below is a picture of the cross section I cut out of my top when installing a roof vent. My top was installed by SMB-I in the spring of 2009.

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Old 09-23-2010, 06:29 PM   #6
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Re: How my Pop-Top Leak was Amended

There are two style tops. Jeff, do you have a smooth top?
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Old 09-24-2010, 03:49 PM   #7
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Re: How my Pop-Top Leak was Amended

Great to see the cross section.

Next question: do the three SMB site construct their roofs the same way?


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Old 08-29-2019, 02:17 PM   #8
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Quote:
Originally Posted by woodbee View Post
jeff00seattle,

Is there any ventilation between the plywood and the roof? To keep out any condensation.

Woody
That is a great question, I am not certain since I did not do the repair.
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Old 08-29-2019, 02:18 PM   #9
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Quote:
Originally Posted by daveb View Post
There are two style tops. Jeff, do you have a smooth top?
Yes, my SMB pop-top is smooth.
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Old 08-29-2019, 02:19 PM   #10
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Quote:
Originally Posted by BroncoHauler View Post
Great to see the cross section.

Next question: do the three SMB site construct their roofs the same way?

Herb
I am not certain. My SMB was constructed in SMB West in 2001.
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