Reply
 
Thread Tools Search this Thread Display Modes
 
Old 07-07-2009, 12:18 PM   #1
Rivet Master
 
Bambi_Bandit's Avatar
 
2008 27' International CCD FB
1964 19' Globetrotter
1955 26' Cruiser Overlander
Austin , Texas
Join Date: Sep 2004
Posts: 602
Images: 12
Step by Step: Replacing OEM skylights with new Custom Maxim Skylights

Problem 1: Original OEM skylights, leaking due to over torqued screws cracking the skylight during airstream manufacturing - replaced in June 2008 at JC... again, over torqued and cracked.....and leaking!

Problem 2: Hot as Hll in Texas. Dometic 15K barely keeping up (with issues of it's own) and direct sunlight making skylight into magnifying glass in trailer.

Problem 3: Storms in Texas able to drop hail size of various sporting goods balls from marble to golf to baseball...Need to ensure best impact resistance to minimize any hail intrusion.

Solution: Custom skylights made to fit current aluminum curb. Maxim skylights. Options of # of Domes and tint (light passthru) and frame (anodized or non), built to Miami Dade/Florida and Texas Coastal Hurricane wind and impact resistant skylights.

Specs on the the "hurricane resistant" model as attached:
Attached Files
File Type: pdf Dade Curb Mount Approval Detail Model (1).pdf (273.7 KB, 720 views)
__________________

__________________
Kevin & Prim Li
Bandit the Siberian Husky (Forever my Girl 1997-2011) & "G" the Min-Pin
Cosmo the Custom 2008 27FB Intl CCD
Maxwell the 1964 Globe Trotter
Name TBD the 1955 Overlander
WBCCI # 6155
AIR # 6155

2nd love - 2006 28' Safari LS
1st love - 2004 19' CCD Bambi
Bambi_Bandit is offline   Reply With Quote
Old 07-07-2009, 12:26 PM   #2
Rivet Master
 
Bambi_Bandit's Avatar
 
2008 27' International CCD FB
1964 19' Globetrotter
1955 26' Cruiser Overlander
Austin , Texas
Join Date: Sep 2004
Posts: 602
Images: 12
Step 1 - remove skylight screws and caulk

(I have 2 skylights on my 27FB international. This thread will show the skylight replacement midship over the bathroom / hall area)

Peel back the caulk on the skylight screws.

Note the cracking on the caulk that is 1 year old from JC? This is what it looks like with the first 6 months in covered storage, followed by 6 months in the elements.

Also note the water on the screw head from the previous rain.

Can we see the large cracks from the over torqued screws?

The silver radiant barier is tucked in the skylight openeing from inside the trailer.
Attached Thumbnails
Click image for larger version

Name:	P6213490 (Large).JPG
Views:	286
Size:	83.2 KB
ID:	83560   Click image for larger version

Name:	P6213492 (Large).JPG
Views:	296
Size:	60.4 KB
ID:	83561  

Click image for larger version

Name:	P6213493 (Large).JPG
Views:	269
Size:	61.9 KB
ID:	83562   Click image for larger version

Name:	P6213495 (Large).JPG
Views:	290
Size:	87.4 KB
ID:	83563  

Click image for larger version

Name:	P6213498 (Large).JPG
Views:	281
Size:	112.3 KB
ID:	83564  
__________________

__________________
Kevin & Prim Li
Bandit the Siberian Husky (Forever my Girl 1997-2011) & "G" the Min-Pin
Cosmo the Custom 2008 27FB Intl CCD
Maxwell the 1964 Globe Trotter
Name TBD the 1955 Overlander
WBCCI # 6155
AIR # 6155

2nd love - 2006 28' Safari LS
1st love - 2004 19' CCD Bambi
Bambi_Bandit is offline   Reply With Quote
Old 07-07-2009, 12:29 PM   #3
Rivet Master
 
Bambi_Bandit's Avatar
 
2008 27' International CCD FB
1964 19' Globetrotter
1955 26' Cruiser Overlander
Austin , Texas
Join Date: Sep 2004
Posts: 602
Images: 12
Step 2 - Pry off with stiff putty knife

Gently work a stiff putty knife under a corner and pry... the rest will follow...

Note I left the radiant barrier in place to keep the AC in best I could during this process.
Attached Thumbnails
Click image for larger version

Name:	P6213499 (Large).JPG
Views:	270
Size:	72.0 KB
ID:	83565   Click image for larger version

Name:	P6213501 (Large).JPG
Views:	267
Size:	77.9 KB
ID:	83566  

Click image for larger version

Name:	P6213502 (Large).JPG
Views:	256
Size:	152.2 KB
ID:	83567  
__________________
Kevin & Prim Li
Bandit the Siberian Husky (Forever my Girl 1997-2011) & "G" the Min-Pin
Cosmo the Custom 2008 27FB Intl CCD
Maxwell the 1964 Globe Trotter
Name TBD the 1955 Overlander
WBCCI # 6155
AIR # 6155

2nd love - 2006 28' Safari LS
1st love - 2004 19' CCD Bambi
Bambi_Bandit is offline   Reply With Quote
Old 07-07-2009, 12:32 PM   #4
Rivet Master
 
Bambi_Bandit's Avatar
 
2008 27' International CCD FB
1964 19' Globetrotter
1955 26' Cruiser Overlander
Austin , Texas
Join Date: Sep 2004
Posts: 602
Images: 12
Step 3 - Scrape the caul off the top of the curb

Take stiff putty knife and scrape the curb. Note that the welds on the corner are not ground down. Existing screw holes will be rough to work with the knife. Wire Brush will help.

Note: newer trailers with skylights installed with double sided tape adhesive versus screws should have welds ground down already.
Attached Thumbnails
Click image for larger version

Name:	P6213506 (Large).JPG
Views:	265
Size:	108.8 KB
ID:	83568   Click image for larger version

Name:	P6213508 (Large).JPG
Views:	285
Size:	151.4 KB
ID:	83569  

__________________
Kevin & Prim Li
Bandit the Siberian Husky (Forever my Girl 1997-2011) & "G" the Min-Pin
Cosmo the Custom 2008 27FB Intl CCD
Maxwell the 1964 Globe Trotter
Name TBD the 1955 Overlander
WBCCI # 6155
AIR # 6155

2nd love - 2006 28' Safari LS
1st love - 2004 19' CCD Bambi
Bambi_Bandit is offline   Reply With Quote
Old 07-07-2009, 12:36 PM   #5
Rivet Master
 
Bambi_Bandit's Avatar
 
2008 27' International CCD FB
1964 19' Globetrotter
1955 26' Cruiser Overlander
Austin , Texas
Join Date: Sep 2004
Posts: 602
Images: 12
Step 4 - Measure your crub

Measure your curb and call / e-mail Maxim with your size. Note to get the outer curb size as well as the curb height.

Note that I measured height with the existing sealant / caulk in place since new sealant/caulk would take approximately the same height.
Attached Thumbnails
Click image for larger version

Name:	P6213511 (Large).JPG
Views:	252
Size:	127.1 KB
ID:	83570   Click image for larger version

Name:	P6213512 (Large).JPG
Views:	255
Size:	99.2 KB
ID:	83571  

Click image for larger version

Name:	P6213513 (Large).JPG
Views:	243
Size:	158.6 KB
ID:	83572   Click image for larger version

Name:	P6213514 (Large).JPG
Views:	249
Size:	102.8 KB
ID:	83573  

Click image for larger version

Name:	P6213522 (Large).JPG
Views:	248
Size:	82.6 KB
ID:	83574  
__________________
Kevin & Prim Li
Bandit the Siberian Husky (Forever my Girl 1997-2011) & "G" the Min-Pin
Cosmo the Custom 2008 27FB Intl CCD
Maxwell the 1964 Globe Trotter
Name TBD the 1955 Overlander
WBCCI # 6155
AIR # 6155

2nd love - 2006 28' Safari LS
1st love - 2004 19' CCD Bambi
Bambi_Bandit is offline   Reply With Quote
Old 07-07-2009, 12:41 PM   #6
Rivet Master
 
Bambi_Bandit's Avatar
 
2008 27' International CCD FB
1964 19' Globetrotter
1955 26' Cruiser Overlander
Austin , Texas
Join Date: Sep 2004
Posts: 602
Images: 12
Step 5 - Strip the old sealant/caulk off the roof and curb

This is the most time consuming part. Take a stiff putty knife and scrape, scrape, scrape... Again, Wire brush will help.

After you have scraped and brushed most of what you can (even with your fingernails) use acetone to clean down to the metal.

Note that you DO NOT want to remove the caulk under the existing curb that is RIVETED down. Just get up as close to it as possible. The existing seal there will be covered with new caulk/sealant.
Attached Thumbnails
Click image for larger version

Name:	P6213531 (Large).JPG
Views:	319
Size:	99.4 KB
ID:	83575   Click image for larger version

Name:	P6213545 (Large).JPG
Views:	321
Size:	100.9 KB
ID:	83576  

__________________
Kevin & Prim Li
Bandit the Siberian Husky (Forever my Girl 1997-2011) & "G" the Min-Pin
Cosmo the Custom 2008 27FB Intl CCD
Maxwell the 1964 Globe Trotter
Name TBD the 1955 Overlander
WBCCI # 6155
AIR # 6155

2nd love - 2006 28' Safari LS
1st love - 2004 19' CCD Bambi
Bambi_Bandit is offline   Reply With Quote
Old 07-07-2009, 12:46 PM   #7
Rivet Master
 
Bambi_Bandit's Avatar
 
2008 27' International CCD FB
1964 19' Globetrotter
1955 26' Cruiser Overlander
Austin , Texas
Join Date: Sep 2004
Posts: 602
Images: 12
Step 6 - New caulk/sealant around curb

Take your favorite caulk/sealant and use like its going out of style. I used 2 tubes of 3M Marine 5200 and spread it like icing on a cake. The curb will NEVER leak now... (Never say never - I'm sure I just jinxed myself now)

***Use Gloves for this process, otherwise all your tools, ladder, and anything you touch will be a mess. Keep spares in your pocket to minimize runs up and down the ladder....****
Attached Thumbnails
Click image for larger version

Name:	P6213550 (Large).JPG
Views:	291
Size:	90.7 KB
ID:	83577   Click image for larger version

Name:	P6213552 (Large).JPG
Views:	282
Size:	48.0 KB
ID:	83578  

__________________
Kevin & Prim Li
Bandit the Siberian Husky (Forever my Girl 1997-2011) & "G" the Min-Pin
Cosmo the Custom 2008 27FB Intl CCD
Maxwell the 1964 Globe Trotter
Name TBD the 1955 Overlander
WBCCI # 6155
AIR # 6155

2nd love - 2006 28' Safari LS
1st love - 2004 19' CCD Bambi
Bambi_Bandit is offline   Reply With Quote
Old 07-07-2009, 12:47 PM   #8
2 Rivet Member
 
Stephen Mick's Avatar
 
2006 28' International CCD
Austin , Texas
Join Date: May 2008
Posts: 87
Images: 1
Kevin,

You're got to stop posting stuff like this. It really make me want to get the tools out and rip into the top of my trailer!

--SM
__________________
Stephen Mick is offline   Reply With Quote
Old 07-07-2009, 12:59 PM   #9
Rivet Master
 
Bambi_Bandit's Avatar
 
2008 27' International CCD FB
1964 19' Globetrotter
1955 26' Cruiser Overlander
Austin , Texas
Join Date: Sep 2004
Posts: 602
Images: 12
Step 7 - Attach new skylight

You have 2 choices here. First, hopefully you will have gotten a new skylight from airstream or your dealer if under warranty and you can now caulk on and carefully screw the OEM skylight on for temporary use while you wait for Maxim to make your new custom skylights, OR, you already know your measurements from previous walks on the roof and have the new skylight from Maxim in hand.

On the skylight over the galley/kitchen, I was able to measure without removing the skylight. Others may have so much caulk on the curb that will require removal of the skylight to get an accurate measurement, as was the case for this skylight here.

I will skip showing the install of the OEM skylight for temporary use as most know how to do that properly without over torquing the screws...

Dry fit your new skylight on the curb. Note that the new Maxim skylights are built with 1/4 in tolerance on each side. This is a nice SNUG fit as compared to OEM.

Using a marker or scratch awl, mark areas where the new skylight will screw in. Note that the new Maxim skylights screw in horizontally on the curb.

Once you have figured out where your new skylight will "sit", remove it and liberally Apply your favorite caulk/adhesive to the top of the curb (not shown). Also apply large blobs of caulk where you marked the screw holes will be on the curb, since you will not be able to access this area once they skylight is on.

Go ahead and glob over the screw head as well... Even though we are using fasteners with neoprene gaskets that seal, you can never be sure...

Sorry for the lack of photos here - it was getting darn hot on that roof and I started to hurry!
Attached Thumbnails
Click image for larger version

Name:	P7023571 (Large).JPG
Views:	315
Size:	64.4 KB
ID:	83582   Click image for larger version

Name:	P7023572 (Large).JPG
Views:	306
Size:	78.0 KB
ID:	83583  

Click image for larger version

Name:	P7023573 (Large).JPG
Views:	324
Size:	98.9 KB
ID:	83584  
__________________
Kevin & Prim Li
Bandit the Siberian Husky (Forever my Girl 1997-2011) & "G" the Min-Pin
Cosmo the Custom 2008 27FB Intl CCD
Maxwell the 1964 Globe Trotter
Name TBD the 1955 Overlander
WBCCI # 6155
AIR # 6155

2nd love - 2006 28' Safari LS
1st love - 2004 19' CCD Bambi
Bambi_Bandit is offline   Reply With Quote
Old 07-07-2009, 01:23 PM   #10
Rivet Master
 
Bambi_Bandit's Avatar
 
2008 27' International CCD FB
1964 19' Globetrotter
1955 26' Cruiser Overlander
Austin , Texas
Join Date: Sep 2004
Posts: 602
Images: 12
Fasteners I used

Since we are going in horizontally and thru caulk blindly into the curb, a self tapping fastener is the ideal. Drilling would be a pain...

I went to home depot and purchased Crown Bolt #10 x 1 1/4 inch self tapping metal fasteners, as well as palram wood screws (metal roofing section) with and EDPM washers.

I then took the washers off the Palram wood screws and put them on the crown bolts. A self tapping fastener with EDPM washer. No drill needed now!!!


Product Information Error Page


Woodtite Woodtite 1 In. - 50 Pc. - 92522 at The Home Depot
Attached Images
  
__________________
Kevin & Prim Li
Bandit the Siberian Husky (Forever my Girl 1997-2011) & "G" the Min-Pin
Cosmo the Custom 2008 27FB Intl CCD
Maxwell the 1964 Globe Trotter
Name TBD the 1955 Overlander
WBCCI # 6155
AIR # 6155

2nd love - 2006 28' Safari LS
1st love - 2004 19' CCD Bambi
Bambi_Bandit is offline   Reply With Quote
Old 07-07-2009, 01:31 PM   #11
Rivet Master
 
Bambi_Bandit's Avatar
 
2008 27' International CCD FB
1964 19' Globetrotter
1955 26' Cruiser Overlander
Austin , Texas
Join Date: Sep 2004
Posts: 602
Images: 12
Finished Product

I opted for a double dome, both bronze) with 7% light transmission, as well as a clear flat on the "inside". total of (3) layers of polycarbonate for protection and better insulation. I also selected the anodized aluminum frame.

Here are the specs of my skylights as made by Maxim, as well as views of the completed install.

Total cost of skylights was ~$300 (~$150 each) 6 tubes of caulk were ~$12 each (on sale at West Marine) and fasteners from Home depot were ~$14.

The skylight lets in a bronze light, which I love as it complements the dark "espresso" colored laminate of the International CCD.
Attached Thumbnails
Click image for larger version

Name:	P7023576 (Large).JPG
Views:	281
Size:	101.7 KB
ID:	83592   Click image for larger version

Name:	P7023578 (Large).JPG
Views:	282
Size:	119.4 KB
ID:	83593  

Click image for larger version

Name:	P7023579 (Large).JPG
Views:	295
Size:	80.1 KB
ID:	83594  
Attached Files
File Type: pdf Kevin Li Dade Curb Mount Approval Detail Model (1).pdf (264.9 KB, 382 views)
__________________
Kevin & Prim Li
Bandit the Siberian Husky (Forever my Girl 1997-2011) & "G" the Min-Pin
Cosmo the Custom 2008 27FB Intl CCD
Maxwell the 1964 Globe Trotter
Name TBD the 1955 Overlander
WBCCI # 6155
AIR # 6155

2nd love - 2006 28' Safari LS
1st love - 2004 19' CCD Bambi
Bambi_Bandit is offline   Reply With Quote
Old 07-07-2009, 03:40 PM   #12
Rivet Master
 
3Ms75Argosy's Avatar
 
1975 Argosy 26
1963 24' Tradewind
Seattle , Washington
Join Date: Aug 2002
Posts: 2,340
Images: 7
Cool Kevin (pardon the pun!). I might just use Maxium to replace my '64 Solordome instead of the fiberglass replacements. I wonder if my stock openers would rivet on the frame too?
Marc
__________________
3Ms75Argosy is offline   Reply With Quote
Old 08-19-2009, 04:33 PM   #13
3 Rivet Member
 
Astroboy's Avatar
 
2007 28' International CCD
West Hollywood , California
Join Date: Mar 2008
Posts: 141
Wow.

Wow. Wow. Wow.

Wow x 100, & more.

I've been staring up my skylight (cracked and duct-taped) for several weeks and pondering about its replacement for something better than an OEM plastic.

Fortunately for me, you beat me to it.

Thank you for the write-up and photos.
__________________
Astroboy is offline   Reply With Quote
Old 08-29-2009, 07:40 AM   #14
1 Rivet Member
 
Currently Looking...
Rockville Centre , New York
Join Date: Jun 2009
Posts: 14
great thing thank u
__________________

__________________
Josie28 is offline   Reply With Quote
Reply

Tags
oem skylights, replace


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off


Similar Threads
Thread Thread Starter Forum Replies Last Post
STEP-BY-STEP Shell-Off Floor Replacement A-Merry-Can Repairing/Replacing Floor &/or Frame 794 04-29-2013 07:49 PM
Step by Step Repair for 1965 Caravel jlovelady Steps 2 12-19-2009 02:23 PM
Skylights on 75 sovereign bdbluegrass Roof Vents, Skylights & Fans 5 08-21-2006 07:26 PM
How About a Collection of Step by Step Repair Procedures? josephhh Airstream Motorhome Forums 27 11-23-2004 06:01 PM
Skylights..... Silvertwinkie Our Community 4 08-14-2003 08:32 AM


Airstream Classifieds



Our Communities

Our communities encompass many different hobbies and interests, but each one is built on friendly, intelligent membership.

» More about our Communities

Automotive Communities

Our Automotive communities encompass many different makes and models. From U.S. domestics to European Saloons.

» More about our Automotive Communities

RV & Travel Trailer Communities

Our RV & Travel Trailer sites encompasses virtually all types of Recreational Vehicles, from brand-specific to general RV communities.

» More about our RV Communities

Marine Communities

Our Marine websites focus on Cruising and Sailing Vessels, including forums and the largest cruising Wiki project on the web today.

» More about our Marine Communities


Copyright 2002-2012 Social Knowledge, LLC All Rights Reserved.

All times are GMT -6. The time now is 09:31 AM.


Powered by vBulletin® Version 3.8.8 Beta 1
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.

Airstream is a registered trademark of Airstream Inc. All rights reserved. Airstream trademark used under license to Social Knowledge LLC.

Airstream News Delivered to your Email!

Stay up-to-date with Airstream news in your inbox!

unsusbcribe at anytime with one click

Close [X]