Dear Dave,
Is this delamination of the front and bottom of the back? Or can it be from sitting in direct sunlight and high temperatures and closed up for the last 4 years, just opened occasionally. —Dawana, 2015 Dutchmen Kodiak
Dear Dawana,
I see this quite often on trailers that are exposed to the elements. I believe it is a combination of heat and moisture, which could be a leak or simply condensation.
The construction method is typically a one-piece outer fiberglass which would have been a Crane Composite Filon with a thin wooden backing material called lauan. Most RV manufacturers use Azdel today, which is a composite material that will not absorb moisture if there is a leak and reduces the risk of delamination but does not totally eliminate it. Under the lauan is block foam insulation, framework, and another inside sheet of paneling with a wallpaper interior covering. All these are sandwiched together with an adhesive between each layer.
Typically the roof to front cap seam is the culprit when it comes to moisture penetration. If the unit has been sitting for several years, I would imagine the sealant has expanded and contracted so many times it has separated and allowed water to penetrate. It doesn’t take much and sometimes the sealant looks good when it contracts so it is hard to tell.
When the moisture penetrates the seam, it seeps down between the layers and excessive heat will make the components swell and allow it to work down further, making the adhesive loosen so there is nothing holding the fiberglass panel to the thin paneling. More heat makes the fiberglass expand then contract when it cools down, and it just keeps going. Delamination is defined as the separation of layers, and this is certainly a classic example.
Can it be fixed?
It can be fixed; However, it is not an easy DIY. You would need to remove the corner trim, roof to front cap trim, and peel back the fiberglass to inspect the damage. If the lauan is not rotten and separated, you may be able to apply an adhesive and roll the fiberglass back smooth. However, looking at the photo, it looks like the fiberglass has stretched and may not go back on smoothly, which means replacing the fiberglass skin.
In some cases, I have found owners that have drilled a small hole in the fiberglass and applied an adhesive with a syringe or small adhesive tube with a tip. Apply the adhesive and roll the skin smooth. Again, I believe your rig is beyond this repair method, but it might be worth a shot.
In either case, you would want to apply pressure to the outer skin while it cures. With a curved front, you could use 2x4s horizontally across the front every two feet with a ratchet strap on both ends pulling it down to a stake in the ground.
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Dave Solberg is a leading expert in the RV industry and the author of the “RV Handbook.”
RVDT2719
Thank you for presenting the problem and discussing how the RV was made and alternative ways of fixing it, Dave. Sounds difficult and expensive. Have a great day and safe travels!