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Water and Rot can cause unsalvagable damage. At times an RV roof replacement is the only fix. An RV owner gets creative and uses ArmorThane to do just that!
Ever wonder what it looks like when you tear off the roof of an RV?
Hopefully, you never have to know. If you do, it means you presumably had water damage, possible damage from falling tree limbs, or other maintenance concerns. RV roof replacement can be one of the most daunting projects to tackle, especially considering the level of labor and expense. It is more common than we would like to acknowledge, given that most RV roofs are not produced with longevity in mind. Water will ultimately find its way in. Sometimes it doesn’t even matter how diligent you are with your maintenance schedule.
ArmorThane RV Roof Replacement
Most RV owners choose to seal or partially repair their RV roof and avoid having to replace it at all costs fully. An avid reader of our blog, onearmyrver decided to go all in and tear off the roof of his 2006 37′ Weekend Warrior 5th Wheel and do a full RV roof replacement after finding significant water and rot destruction. After tearing off the roof, he moved on to remove all the low-quality insulation after the grueling process of ripping off the roof. Not surprisingly, only around 50% of the roof was insulated. We assume the factory never anticipated an owner would tear off the roof to see the shoddy work.
This is when the RV roof replacement got interesting. Once down to the bare structure, both spray and traditional insulation were installed where needed. Then, plywood was installed over the roof construction, which added supplementary weight (the repair increased the RV by 380lbs). Lastly, ArmorThane was used to coat the roof instead of the typical rubber roof material in an interesting twist. Though unorthodox, the premise is a great one. ArmorThane is a rugged weather-resistant material that seals permanently, locking out dust, dirt, and most importantly, water.
When you consider the cost of the typical 2006 fifth wheel, you can see why most folks decide not to do RV roof replacement as it is, cost-effective. The cost for a more conventional rubber roof does vary, but in this case, it would have run more than $5,000. The ArmorThane coating, which ran from the back of the fifth wheel to the front end and over the front, only cost $3,500. Also, the roof should last for many years without any problems as long as the vents/AC unit is correctly sealed and maintained.
Have you done an RV roof replacement? Would you consider ArmorThane bedliner material as an option? Please share in the comments below.
Related guides
RV roof materials estimator
Enter your roof size and what is mounted on it for a rough shopping list of coating, sealant and tape.
A planning estimate, not a quote. Coverage varies widely by product, surface and application thickness, so check each label and buy a little extra.
How This Owner Replaced His Fifth Wheel Roof
The steps one owner followed on a 2006 37-foot fifth wheel, in the order he did them.
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Frequently asked questions
Can you do a DIY RV roof replacement yourself?
Yes, but go in with your eyes open. The owner in this post tore the roof off a 37-foot fifth wheel, pulled the old insulation, re-insulated and laid new plywood before the roof was coated. Ripping off the roof alone was grueling, and most owners choose to reseal or partially repair rather than take on a full replacement.
How much does an RV roof replacement cost?
It varies, but here's one real example. On a 2006 37-foot fifth wheel, a conventional rubber roof would have cost more than $5,000. The owner went with a sprayed polyurea coating instead, running from the rear over the front, for $3,500. Given what a fifth wheel that age is worth, many owners decide full replacement isn't worth it.
How much weight does a new RV roof add?
More than you might expect. In this rebuild, new spray and traditional insulation plus a plywood deck over the roof framing increased the fifth wheel's weight by about 380 pounds. If you're planning a similar build with plywood and added insulation, account for that extra weight before you commit to it.
Can you use bedliner polyurea instead of a rubber RV roof?
This owner did. Instead of a new rubber membrane, the roof was coated with spray-applied polyurea, the rugged bedliner-type material, which is meant to seal out dust, dirt and water for good. It's an unconventional choice, and it holds up only as long as the vents and AC unit are sealed correctly and maintained.
What do you find when you tear off an RV roof?
Often, more trouble than you expected. This owner found significant water and rot damage and, once the roof was off, low-quality insulation covering only about half the roof. Water eventually finds its way into most RV roofs, sometimes no matter how carefully you keep up with maintenance, so expect surprises once the membrane comes up.
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