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Old 05-16-2013, 07:40 AM   #1
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2005 31' Classic
Sunrise Beach , Missouri
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Repairing Cracks in AC Cover

While working on the roof replacing our skylights with Maxim skylights we noticed a couple of three inch cracks in the plastic shroud for the air conditioner. Nothing serious yet, but we want to stop this cracking and prevent future leaks. Your suggestions for repairing these cracking and preventing them from getting bigger would be appreciated.
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Old 05-16-2013, 07:49 AM   #2
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I would just replace it. The UV from the sun is hard to get ahead of.


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Old 05-16-2013, 08:17 AM   #3
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If this is the original shroud it is very susceptible to becoming brittle due to sun exposure. You can stop drill the ends of the cracks and epoxy some small braces on the inside as a temporary fix but the best fix is to replace the shroud. I replaced mine with the Icon aftermarket shroud and have been very pleased. They are on sale, about $100, this week at the following address.

Air Conditioner Shrouds | AC Shrouds | RV Air Conditioner Covers
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Old 05-16-2013, 08:32 AM   #4
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I've got a crack around one of the attachment screws on mine (2002 ASCL 31') which I'm going to repair with fiberglass on the underside, just haven't gotten around to it yet; so you might pick up a fiberglass repair kit from an auto parts store and try that.
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Old 05-16-2013, 09:54 AM   #5
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If your Penguin shroud uses the small head screws (newer models use a washer-head screw), you might use some stainless steel fender washers between the screw heads and the outside of the shroud to equalize the pressure points and spread the cracking force over a larger area. Works for me.........and my clients!
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Old 05-16-2013, 10:34 AM   #6
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I've had excellent luck on plastic repair using West Systems G-Flex epoxy. It is specially formulated for plastic. Rough up the back side with 80 grit , paint some epoxy on the surface and lay fiber glass cloth in it. Add a little more G- Flex and work it in with a body filler plastic spatula. Regular epoxy and polyester resins don't seem to work as well as the G- flex on plastic. I fixed the hood on my John Deere lawn tractor after a major break and it has held up well. Any marine supply should have the G-flex. Be cheaper than a new one.
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Old 05-16-2013, 12:23 PM   #7
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Quote:
Originally Posted by withidl View Post
I've got a crack around one of the attachment screws on mine (2002 ASCL 31') which I'm going to repair with fiberglass on the underside, just haven't gotten around to it yet; so you might pick up a fiberglass repair kit from an auto parts store and try that.
Quote:
Originally Posted by lewster View Post
If your Penguin shroud uses the small head screws (newer models use a washer-head screw), you might use some stainless steel fender washers between the screw heads and the outside of the shroud to equalize the pressure points and spread the cracking force over a larger area. Works for me.........and my clients!
Quote:
Originally Posted by 68 TWind View Post
I've had excellent luck on plastic repair using West Systems G-Flex epoxy. It is specially formulated for plastic. Rough up the back side with 80 grit , paint some epoxy on the surface and lay fiber glass cloth in it. Add a little more G- Flex and work it in with a body filler plastic spatula. Regular epoxy and polyester resins don't seem to work as well as the G- flex on plastic. I fixed the hood on my John Deere lawn tractor after a major break and it has held up well. Any marine supply should have the G-flex. Be cheaper than a new one.


I reinforced ours with epoxy and glass cloth behind the blue border, all the way around. Also some cracks in front and top. Been a few years now, holding up pretty well but a new shroud from the link above will be needed before too long.

Bob
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Old 05-16-2013, 01:21 PM   #8
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I second the G-Flex from West ; good stuff.
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Old 05-19-2013, 11:38 AM   #9
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I've got a new shroud for sale from Icon out of Canada that fits the Dometic Penguin Duo Therm AC , I just got it this spring. $75
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Old 05-19-2013, 03:44 PM   #10
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It must be that blue strip Robert????
When I look at your cover it looks to be sitting higher on the air unit than mine, but when I dig up a picture of mine, I guess it is mounted the same.

For $100 bucks from CW, if its cracked now, I don't think its worth the time to chase the problem around the old shroud. (been there -- done that.)



Dave

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Originally Posted by ROBERT CROSS View Post

I reinforced ours with epoxy and glass cloth behind the blue border, all the way around. Also some cracks in front and top. Been a few years now, holding up pretty well but a new shroud from the link above will be needed before too long.

Bob
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Old 05-19-2013, 03:54 PM   #11
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Mine shot craps after 3 years of outside storage with cracks starting to radiate from every screw hole. Once pulling it off I didn't realize how brittle overall it had become. The thing to keep in mind is that the Penguin cover sits against some foam baffles that direct air flow through the system. If that thing flies apart when you are on the road (and I've seen my share while on the Interstate), your air conditioner will not function properly until you get a new cover on. Sometimes its better to bite the bullet instead of trying to save the cover, get a new one. All it takes is something to strike it in its brittle state.

Interesting that when talking to Dometic, they only warrant replacement covers for 6 months.

Jack
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Old 04-16-2016, 03:16 PM   #12
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just when through the same issue with brittle as heck A/C cover. This is a new to us unit, 2005 that has spend winters in FL and for the most part summers in Maine.

I was on roof checking out stuff and seeing how I have a HVAC background was intrested in the AC unit. So I started removing the screws and grabbed the edges to put it of and SNAP a large chunk of the shroud came off in my hands..

I got it off with out breaking off much more and went on line to find a replacement. Got one ordered and it arrived from PPL in 2 days.. $96 with shipping. The foam was crumbling and coming off in my hands.

The new cover a nice polar white was AWESOME.. the old one appeared to be a beigeish look.

The kit came with new foam tape and i replace the old rusting screws with SS ones

While I had the top off I used some nonacid coil cleaner on the condenser coils. the foaming is letting you know the cleaner is doing it job.


I saw the cover for the indoor or evap coil so I proceeded to remove the cover to that.. Now I can see inside the AS. I used a wet dry vacuum to control water or flow and to get water that might overflow to the inside.

that coil foamed up good as well.. it common for these unit to never be serviced along the way.. most of the time the cooling goes down and down till you take it to the local RV dealer who first thing is to replace it.




after getting the system cleaned up I put it all back together and getting ready to hit the road with my "new" 10 yr old system..

stupid photos.. right click to open in in tab to see them..
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Old 04-16-2016, 03:55 PM   #13
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We replaced the air conditioner shroud on our 2005 19' Bambi. I leaned on the air conditioner to steady myself while on the roof, and my hand went right through the shroud. We got our replacement on Amazon:

Amazon.com: Dometic Penguin A/C Replacement Shroud fits 11,000 BTU & 13,500 BTU. (This is a replacement for older Penguin models; and it does NOT replace Penguin II low profile models).
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Old 04-16-2016, 04:08 PM   #14
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Google Icon website. They make covers out of much better material. I've had one for 5 years and it is still like new.
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