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In this section we share and discuss various technical advise that help fellow campers in general or regarding specific questions.

1988 Caravette 5 replacement roof

replies: 17
views: 234
18 Jul 2021 @ 22:48:25 pm
Caravette5
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Hello all.

I have an 1988 Caravette 5 caravan that had a leak in the pop up roof that caused massive damage.

I'm unable to repair my existing roof, I need to replace it. I am planing to build a custom pop up roof from fibreglass (roof will be solid and not joined as per attached drawing)

I'm Planning on creatinf a mould with 3mm mdf with the correct shape and size. Then once the fibreglass is done, install a new frame with 16mm mdf and fibreglass the new frame as a part of the new roof for support and structure then a new ceiling with 6mm MDF and paint it white.

My question is, would the fibreglass release from the mdf mould if I use Pva releasing agent? Or is the mdf to porous ?

Second question, I'm planning on installing new led strip lights in an aluminum channel. Is there anything else you would recommend I do additional?

Thank you very much. Lookin forward to you advice and ideas.

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19 Jul 2021 @ 07:31:25 am
Duncan
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Do you want to build your own ? Why not try for a new one as the moulds might still be available.

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19 Jul 2021 @ 09:19:00 am
Leon
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I would make one by using the frame you have and checkered plate panel for the outside.  Use alu Sq tubing and connect-it for the inside frame 

Sonder Jesus is ek niks! ! ! !
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19 Jul 2021 @ 10:53:03 am
Caravette5
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Do you want to build your own ? Why not try for a new one as the moulds might still be available.

Yes, I want to do it myself, Im also going to drop It 20mm to fit through my garage easier. 

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19 Jul 2021 @ 10:55:56 am
Caravette5
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I would make one by using the frame you have and checkered plate panel for the outside.  Use alu Sq tubing and connect-it for the inside frame 

I was looking at using cromadex sheets to make it out of metal. The sheets are very cheap R900 for a 1225mm x 3000mm to cut it have to give me x2 sheets of 1225mm x 1500mm.

But wast sure how to do the bullnoses in front and back. 

 

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19 Jul 2021 @ 11:03:17 am
Wetkit
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My very old 93 Penta had a similar roof that failed.

I used the fiber glass sheeting they use for cold rooms.

It was 35mm thick with foam core on the inside. This is both strong, light and great insulation. You also buy the alu siding with the sheet and it was very easy to work with and glue everything together.

Good Luck!

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19 Jul 2021 @ 11:53:11 am
Bostoe
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Sterkte met projek ek hou die draad dop

Haak daai wa kamp bly koning
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19 Jul 2021 @ 12:22:16 pm
Fred
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I must say Ed's (Wetkid) solution sounds very good to me.  You would probably get a much neater product than forming the roof in fiberglass and will probably also be a much easier and quicker job.  And the heat isolation sounds a good bonus.  If I had this situation, I think this would have been the way I would have gone.

Het is beter rijk te leven dan rijk te sterven
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19 Jul 2021 @ 12:41:59 pm
Wetkit
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19 Jul 2021 @ 12:53:29 pm
Chuck Norris
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Welkom hier op die forum.

 

Al weer oppad iewers heen.
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19 Jul 2021 @ 14:13:55 pm
Fred
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I have read through your 2018 thread and I must say, the work you did looks extremely professional and perhaps even better than the OEM roof.  It seems the new roof must  have been quite light.  Was the gaslifters still really necessary?

Het is beter rijk te leven dan rijk te sterven
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19 Jul 2021 @ 14:27:01 pm
Caravette5
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Welkom hier op die forum.

 

 

Baie dankie!

 

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19 Jul 2021 @ 14:29:06 pm
Caravette5
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Thank you very much.

I'll try and find out where I can get the iso boards.

The ones I could find was too think 100mm if I can remember correctly. 

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19 Jul 2021 @ 14:30:34 pm
Caravette5
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Sterkte met projek ek hou die draad dop

Baie dankie. Ek sal. Progress fotos. Opsit soos ek aan gaan. 

My projek begin by die dak. Ek gaan alles oor doen binne

Van vloer tot dak gaan alles nuut wees. 

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5 days ago @ 22:04:56 pm
AltydKampTyd
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All the best Werner, hope it comes out well!

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4 days ago @ 14:20:16 pm
Paddyandpaul
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Werner if you make your own fibreglass roof, after you have applied the pva release agent and it has dried, apply clear floor wax liberally then polish it. Used to do that with sculpture moulds Ì did many years ago in plaster of paris and the fibreglass sculpture released easily. Also you can get a resin gel coat that you apply first in the mould as it does not run off the sides and after it has dried apply the gp resin with chop strand mat.

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4 days ago @ 16:20:40 pm
KD
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If you use 3 mm mdf you will need to build a support framework. 

I built a flat deck for my bakkie with hatches. I used white chipboard to make the moulds. It will hold its own shape. Just put it on the floor. Body putty for the curves. Stay away from tight corners. Sand smooth. Apply mould release, gel coat, fibreglass and resin with a roller. Speak to your supplier. You will need an extra pair of hands for the glass. A couple of pieces of half round while glassing for support. 3 evenings. Finish inside of your roof. Remove from the mould. Was off mould release with water. Use the chipboard to build your wife a cupboard.

I would make the roof as large as possible to keep rain off the canvas surround. The height will be decided by the lifting mechanism and canvas surround. 

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4 days ago @ 19:48:23 pm
Caravette5
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If you use 3 mm mdf you will need to build a support framework. 

I built a flat deck for my bakkie with hatches. I used white chipboard to make the moulds. It will hold its own shape. Just put it on the floor. Body putty for the curves. Stay away from tight corners. Sand smooth. Apply mould release, gel coat, fibreglass and resin with a roller. Speak to your supplier. You will need an extra pair of hands for the glass. A couple of pieces of half round while glassing for support. 3 evenings. Finish inside of your roof. Remove from the mould. Was off mould release with water. Use the chipboard to build your wife a cupboard.

I would make the roof as large as possible to keep rain off the canvas surround. The height will be decided by the lifting mechanism and canvas surround. 

Thank you very much.

I will most definitely support the structure. 

I'm Planning on rounding the corners with body putty because I don't want the sharp corners. 

I spoke to Mike from Fiberglass resin company in Boksburg. Gave me great advice And fantastic pricing. 

Thanx for the advice on the size, I will definitely increase the size om the roof. 

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