Free 7 Day Trial RV GPS App RV Trip Planner Campground Reviews RV Maintenance Free 7 Day Trial ×
 


Reply
 
Thread Tools Search this Thread Display Modes
 
Old 02-28-2020, 04:07 PM   #1
2 Rivet Member
 
2006 28' Safari
1948 22' Liner
1989 34.5' Airstream 345
Jamul , California
Join Date: Sep 2006
Posts: 54
Images: 17
2005 Interstate 22 roof repair

I need to weld in a patch on the roof of my, new to me, 2005 Interstate, anyone have any idea what gauge of steel and coating (galvanized?) was used when these sprinters were built?


Thanks, Mike
Lychgate is offline   Reply With Quote
Old 02-29-2020, 09:42 AM   #2
Rivet Master
 
Lotus54's Avatar
 
2006 22' Interstate
Port Angeles , Washington
Join Date: Sep 2016
Posts: 858
I do not believe the sprinter roof was galvanized at all.
I would guess it is just mild steel of a fairly thin gauge. Easy to measure.

Harder part of the repair may be access to both sides and not causing a fire with the welding. I donít know where your trouble area is- but I suspect taking any of the inner ceiling down would be difficult without damaging it.

Other options could be cutting and riveting- but making sure it does not rust again would take some thinking.

Just some ideas, I have not tried any body repair at all on my T1N.

Mark
Lotus54 is offline   Reply With Quote
Old 02-29-2020, 10:00 AM   #3
Rivet Master
 
Wabbiteer's Avatar
 
1973 27' Overlander
1972 29' Ambassador
Itasca , Minnesota
Join Date: Apr 2006
Posts: 2,044
Images: 2
Blog Entries: 2
Actually - between an act of Congress Mandate (for longevity) AND with the new high-strength steels being so thin (for fleet mileage) any rust would perforate rapidly... all body sheet metal on vehicles should be considered to have had a* galvanizing process.



Now whether or not that process resembles anything out of the past is another subject, the modern version being something more like a molecular thin bonding layer for primer top coating is more likely. Anyhow, whatever it is a normal sanding to bright metal underneath will erase the OEM coating but still stay upwind when the arc//torch is dancing...
__________________
The days are short and the night is long and the stars go tumbling by.. . ~Airstream~
Wabbiteer is offline   Reply With Quote
Old 03-01-2020, 10:45 PM   #4
2 Rivet Member
 
2006 28' Safari
1948 22' Liner
1989 34.5' Airstream 345
Jamul , California
Join Date: Sep 2006
Posts: 54
Images: 17
Thanks for the input, I appreciate it.
Lychgate is offline   Reply With Quote
Old 03-02-2020, 04:42 AM   #5
Rivet Master
 
InterBlog's Avatar

 
2007 Interstate
League City , Texas
Join Date: Oct 2014
Posts: 5,610
Question might be easier to answer in full if there was a description of where and why the patch needs to be made.
InterBlog is offline   Reply With Quote
Old 03-02-2020, 07:47 AM   #6
2 Rivet Member
 
2006 28' Safari
1948 22' Liner
1989 34.5' Airstream 345
Jamul , California
Join Date: Sep 2006
Posts: 54
Images: 17
The PO used some kind of patch material that cured like plastic in a couple spots. Very hard and snaps like plastic when you break it apart. The worst of it is at the middle seam on the drivers side. Here are a couple pictures. You can see the light cream color patch material. At the mid seam they painted it. That is the stuff that caused the issue I believe. I think it allowed moisture to sit under the patch and destroy the metal. The grey material is normal RV sealer and those areas are fine.

Mike

I am guessing it started out like the pics that Interstateflyer had in this thread:

https://www.airforums.com/forums/f24...ate-28421.html
Attached Thumbnails
Click image for larger version

Name:	IMG_0754.jpg
Views:	13
Size:	209.9 KB
ID:	362383   Click image for larger version

Name:	IMG_0756.jpg
Views:	10
Size:	244.6 KB
ID:	362384  

Click image for larger version

Name:	IMG_0751.jpg
Views:	10
Size:	219.8 KB
ID:	362385   Click image for larger version

Name:	IMG_0743.jpg
Views:	10
Size:	264.9 KB
ID:	362386  

Lychgate is offline   Reply With Quote
Old 03-02-2020, 11:09 AM   #7
Rivet Master
 
InterBlog's Avatar

 
2007 Interstate
League City , Texas
Join Date: Oct 2014
Posts: 5,610
Welcome to our world, Lynchgate.

Some time back, I started this other thread on exactly that problem, only to get distracted by life's many heavy responsibilities such that I did not expound on the problem.

I never did post pics of what I found, which thankfully was nowhere near as extensive as what YOU found. We had incipient corrosion of the same type. We had one tiny perforation that was starting to allow rainwater in, plus a patch of rust around each of the rear rack feet.

I sanded it, phosphated the hell out of it, then POR-15'd the hell out of it, then Rustoleum'd over the POR-15, then re-caulked it within an inch of its bloody life.

But those were intended to be stopgap measures only. Just to hold us over until we find the time to do the REAL work (we are big DIYers).

The entire roof rack needs to come off and get replaced. But we have a solar array up there, so that's a big job. My husband is a Mech E and he has a design in mind to replace it, but that's for the future.

I digress. Your damage is obviously too extensive to be patched with similar bubblegum, even temporarily.

The only other person of whom I'm aware who had to do a similar roof patch is Maggie (Lily&me), because of analogous corrosion around an antenna. She contracted the work out, and if she could chime in here, maybe she would have some suggestions for you.

But wait - there's more.

There's also the issue of how much damage you might have behind your finishes because of the extent of that mess.

Of particular concern is the plywood subfloor. If a lot of water worked its way all the way down into it, you might have an undiscovered mess. Another user on here a couple of years back discovered that his subfloor had essentially been reduced to the consistency of coffee grounds because of rot. I never did learn what became of him / them - AFAIK, he stopped communicating on this forum. But he had very little structural integrity left in the floor and that's a big, big problem.

So, you might want to check the van widely before you undertake any work, in order to first confirm that it's not already a write-off that is not worthy of at least the paid investment that it would take to render it whole (extensive DIY would come with a different calculus).

I hate to put it in such stark terms, but there's just a lot that can flow from that degree of roof damage. Crap rolls downhill. So does water.

Keep us posted, please.

EDIT: Here's the previous thread about extensive damage to the floor of the other owner's 2005.

https://www.airforums.com/forums/f24...nt-170067.html
InterBlog is offline   Reply With Quote
Old 03-03-2020, 05:59 PM   #8
2 Rivet Member
 
2006 28' Safari
1948 22' Liner
1989 34.5' Airstream 345
Jamul , California
Join Date: Sep 2006
Posts: 54
Images: 17
I will give an update when I start the permanent repairs. Right now I have some 4Ē enternabond tape over the bad areas. I have some travel to do and cannot get to it until I get back. Thanks for the reply.

Mike
Lychgate is offline   Reply With Quote
Old 03-03-2020, 08:13 PM   #9
Rivet Master
 
2006 22' Interstate
League City , Texas
Join Date: Jan 2015
Posts: 695
Cancer sucks. T&Ps on the vanís pending surgery.
LB_3 is offline   Reply With Quote
Reply


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
Roof Welding repair 2005 AI mid-bath mrcolin2u Sprinter and B-van Forum 5 09-17-2018 09:11 AM
Anyone use liquid roof for fiberglass roof repair? 442 john Airstream Motorhome Forums 4 01-02-2013 01:23 PM
2005 Interstate roof rust gradygal General Repair Forum 2 12-21-2008 05:12 PM
Roof repair advice - hole in roof 1956 vintage casaalumina Roof 5 10-05-2008 10:24 PM
Roof Rust on 2005 Interstate interstateflyer Sprinter and B-van Forum 15 03-09-2007 07:41 AM


Featured Campgrounds

Reviews provided by

Disclaimer:

This website is not affiliated with or endorsed by the Airstream, Inc. or any of its affiliates. Airstream is a registered trademark of Airstream Inc. All rights reserved. Airstream trademark used under license to Social Knowledge LLC.



All times are GMT -6. The time now is 10:27 PM.


Powered by vBulletin® Version 3.8.8 Beta 1
Copyright ©2000 - 2021, Jelsoft Enterprises Ltd.