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Old 03-03-2012, 05:48 PM   #1
OB1
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1999 35' Cutter Bus Diesel Pusher
Box Elder , South Dakota
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Question Cutter roof separation from side

I have a 1999 Cutter 35 and the metel that attaches the roof materal to the fiberglass side of the coach has become loose. Its the metel strip that the awning is also attached too. The metal appears to be firmly attached to the roof materal but has lifted away from the side. It looks like it was held on to the side with rivits that have come loose. They may be pop rivits, at least they look like it. I would like to repair it myself but am not sure how it should be done. Pop rivit it back or use screws to fasten it back on? I could sure use some good advise from someone who has experienced or knows about a solution to the problem.
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Old 03-04-2012, 12:31 AM   #2
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Welcome to the Airforms OB1.
Your problem is not one that is seen everyday. Is this a diesel pusher wide body, or is it a Ford or Chev gas front engine?
A picture of the problem would help raise interest and discussion.
Where is the problem at? Front, back, midship???? over the door? is the door front or midship?
Has there been water damage in that area?
Again, some pictures would help as it is not a common complaint.

Dave.

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Originally Posted by OB1 View Post
I have a 1999 Cutter 35 and the metel that attaches the roof materal to the fiberglass side of the coach has become loose. Its the metel strip that the awning is also attached too. The metal appears to be firmly attached to the roof materal but has lifted away from the side. It looks like it was held on to the side with rivits that have come loose. They may be pop rivits, at least they look like it. I would like to repair it myself but am not sure how it should be done. Pop rivit it back or use screws to fasten it back on? I could sure use some good advise from someone who has experienced or knows about a solution to the problem.
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Old 03-04-2012, 07:32 AM   #3
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Hi OB1, I would like to learn more about this project, just in case I need to do some similar work. Give us a little more information as Dave asked and some pictures would be a great help.

If you need help with the picture post check this link:

Airstream Forums - FAQ: Reading and Posting Messages
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Old 03-04-2012, 08:33 AM   #4
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1999 35' Cutter Bus Diesel Pusher
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Thanks for the advice. I will try to get a picture today. The Cutter is a deisel pusher wide body. Thanks again for you intrest and advice.
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Old 03-04-2012, 09:16 AM   #5
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Another roof with "issues"



Link to thread:

http://www.airforums.com/forums/f312...ues-66664.html

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Click on the link to see a picture of the Sioux River falls near my home.
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Old 03-04-2012, 10:46 AM   #6
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OB1's Cutter should not have the same rust prone structure pictured above. The roof and walls should be of aluminum construction. This can be verified by taking a vent off the inside of the roof mount air conditioner and looking to see the framing there.

When we get to see the pictures, I suspect this is the result of water ingress and the resulting swelling of the luan pushing out the f/g panel.

Waiting for the pictures.

Dave
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Old 03-04-2012, 05:02 PM   #7
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Smile

Here are the pictures requested. That is if I have done this right, my first time post and upload. The problem is both sides and from front to back. The metel strip has completly let go or has loosened significantly and will let go. I also inclded a close up of a rivet I pulled from the metel strip. It came out very easy. I sure appreciate everyones interest and hope someone can help. Thanks Again.
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Old 03-04-2012, 06:27 PM   #8
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OB1: You have a real problem, that I have no experience with. You say both sides of the motorhome have the same symptoms??
I think you are going to need more than rivets to repair. The body shop industry has "Huck Bolts" that you are going to need to pull everything together. They use them to fasten heavy frames, among other things, in the trucking industry.
This unit must have experienced some type of trauma in the past. High wind tore off the awnings???

Sorry I have no good news for you.

What about the body to frame? Are there any signs of movement there? This almost looks like the unit was torqued.

Dave
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Old 04-08-2012, 08:24 PM   #9
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There may be plywood rot (a disaster) or not but that is probably not the cause of the pop rivet letting go. My guess is that AS used the wrong grip length rivet that never pulled the gutter to the aluminum frame or the hole was drilled too big. Try a stainless steel rivet 1/8 diameter and at least 1/16 longer and see if that will hold tight. If it still lets go, try a 5/32 or even a 3/16 diameter aluminum rivet about 1/16 inch longer and drill to exactly the rivet diameter. You might need to buy or borrow a rivet tool depending on the rivet material because these rivets are hard to pull with a simple tool.
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Old 04-09-2012, 11:17 PM   #10
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1998 30' Cutter Bus (Chevy)
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I had the same problem with my 98 cutter, I drilled pilot holes between
the factory rivets, then used stainless sheetmetal screws to pull
the layers tight. No problem for 4 years, I do check that area often.

hopefully this info will help.

Jim
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Old 09-12-2013, 10:52 AM   #11
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Petaluma , California
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My Cutter has the same problem. The only stable gutter piece is the big one over the awning. I suspect that this one was mounted much more securely at the factory. Anyhow, I pulled out the bad rivets, drilled holes for the next size rivet, and popped some new rivets in there. Not too hard of a repair!
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Old 07-02-2016, 10:41 AM   #12
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1999 35' Cutter Diesel Bus w/slide
Madera , California
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Hi all,

Rather than start a new thread on the same topic I would like to piggyback on this one. Wife and I are proud new owners of a 35ft cutter with this same issue. Luckily it appears this unit was garaged for most of its existence.

I plan to re rivet the gutter as has been posted above. It sure seems like this was caused by poor rivet choice, bad substrate material choice, or a combination of the above. The pulling away seems to have been caused by the awnings applying outward force when deployed.

Couple of questions:

1- what is the substrate material the rivet is supposed to set against?

2- did any of you apply any sort of sealant to the joint before re riveting, and if so, what product would you recommend?

Thanks all in advance.
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Old 07-03-2016, 12:12 PM   #13
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I used a sealant on the rivet, applied to the inside stem before riveting and a dab on the hole for good measure. The sealant I used was Loctite Stick and Hold. My repair is still holding.
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