Marquis roof/sidewall connection details

[John Fitzgerald]

After repairing the roof/sidewall at the rear of my '95 Marquis last fall and then seeing it leak again this winter, but not as bad, I am not happy obviously.  Does anyone have a drawing that shows a section view of the roof/sidewall construction that shows how it was actually built?  There is no way that I can actually see how the joints are made due to everything being covered up.  I had the rusted screws that are common, and the loose pop rivets, but I want to know how it is actually constructed so I can do a more permanent repair.  It seems there is a gap between where the edge of the roof meets the sidewall which makes the roof able to flex too much and break the sealant there.  I am planning a long trip in two years, and want to return the body shell to like new so I don't need to be repairing in on the road.  I guess you could say my coach is currently in port for a major refit.  Thanks.

[Darell T Hostland]

You have to take all the screws out of the metal strip. Remove the metal strip. On one job there was no sealant under the strip for about 6 inches above the drivers window and about 18 inches over the door. Clean all old sealant off the strip and on the wall behind the strip. There is a small gap between the wall and roof covering. You should see the wall and roof covering as two different pieces. This gap should be full of the new sealant.Try not to bend the metal strip while removing it. Do booth sides of the rv. Put a sealant like lexall in the metal trip and install all the screws again. Replace all rusted out screws. Drill new holes and put new screws. Replace plastic filler back into the metal strip. On a very bad roof to wall joint I put Diseal  patching tape from dicor products over the top part of the metal strip. Not over the plastic filler strip. The tape has a fabric cover over the top and I painted this to match the roof color. The paint should be flexable so it wont crack. It has not leaked for 5 years many miles and temperatures from -40 to 90+. This is one job I did and forgot to take pictures of the repairs.

[John Fitzgerald]

What do the screws that attach the 'gutter' screw into?  It is either the aluminum framing of the side wall or some part of the roof composite assembly embedded in the fiberglass. I have taken the whole rear section of the metal seam cover off of both sides and used new screws.  My thought was to put some sort of foam backer rod material in the gap, then use a high performance urethane like Sikaflex to fill the crack.  Then install the 'gutter' and use one of the high performance RV sealants under it and then run a bead where it meets the roof at the top.

I really am trying to get the outer edge of the fiberglass roof more rigid where the metal gutter seats against it.  I don't like the fact that I am trying to seal an edge the moves when I push it in.

[William Jordan]

I have had several shops work on this.They all say its a problem.  Any owner 2000 ish should be aware this is a major and I consider primary leak point. You won't notice it until it comes through the inner wall covering. The gutter strip is  as noted the blend point of the roof and the wall. the screws used rust out and are leak points. I believe dissimilar metals like screws, aluminum/steel wall frames, etc may be an issue. removing the vinyl cover strip you can see the issue.

[Dan Johnson]

John,  Is this on the rear cap or front? Do you have a picture?

[John Fitzgerald]

It is both sides from rear to front, and perhaps where at the rear cap joint that is covered by an aluminum strip running down to the lower side 'rail'.  I will not be able to send out photos till at least Thursday due to my work schedule.

[Keith Moffett Co-Admin]

John and all;
Our 2002 had exactly this issue.  BCS explained that the factory installed the gutter with double stickey tape behind but the last 6 feet on each corner were left un glued until the end caps were installed.  Some units the film was not removed after the end caps were installed and so it never sealed. 
The fix was to remove the gutter and all the stickey residue.  Then put new on and reattach the gutters.  Then screw them down every couple inches with new stainless screws and then caulk as well.
Ours never leaked after.
There was also a leak in the patio awning box that was character of the 2000 or so Beavers.  The awning caused a leak over the entry door and along the passenger side wall inside.  The fix was almost all labor.