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Old 01-31-2015, 06:11 PM   #1
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Reinstalling fiberglass interior endcap - holes not aligning

Putting interior skins back in, starting with my fiberglass endcap (it was the last to come out. The holes across the top of the window align as do the ones on the left and top left, but the top right and right side are off by 1-2 inches and no amount of shoving will get them where they need to be.

My best guess is that over the months that I have had it out resting on it's top edge it's warped. Anyone think if I get it really hot in there, maybe take a hair dryer to it, it might make it more plyable?

My only other guess is that some pex piping that I put in the walls is bulging out a slight bit and throwing it off.

How important is it to align with the original holes?
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Old 01-31-2015, 07:11 PM   #2
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It looks like you put the insulation all the way around the end cap area, same as we did, we then had to remove some in places where it did not fit. I know you really don't want to hear this, but take down the end cap and find where end cap is denting the insulation and remove a layer.
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Old 01-31-2015, 08:27 PM   #3
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DFlores, yes I did and I almost went with 1" thick boards to leave extra room but ended up rolling the dice with 1.5". Since only the side with the pex piping is off I am thinking that must be the culprit. There's only one layer but I can shave it down. Fortunately I didn't do too many rivets yet so not that much to drill out.

Will report back how it goes. Thanks.
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Old 01-31-2015, 08:31 PM   #4
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Get yourself some clecos and cleco pliers so you can test fit pieces, you will need them for the large upper skins as well
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Old 02-01-2015, 02:29 PM   #5
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I'll be in the same place soon so it's helpful to anticipate the problem.
Pex piping between the walls? If water piping, is that where it was found? Would it be easier to keep from freezing or to find and repair any leaks if it were inside of the inner wall?
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Old 02-01-2015, 04:11 PM   #6
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Reinstalling fiberglass interior endcap - holes not aligning

Heat will generally not affect fiberglass as far as pliability.


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Old 02-02-2015, 09:03 AM   #7
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Yeah, going with 1.5" foam board was a mistake. After shearing down a couple of high spots that I thought were the culprit I ended up tearing it all out. Then I could see that the hole were lining up and that the fiberglass protruded into the wall space in certain spots. Had to make some major mods and finally got everything lined up.

JR, I ran some pex from where I plan to put the H20 tank over my door to the future wet bath since there would be no clean way to hide it otherwise.

Hopefully the other end cap goes smoother.
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