Dear Dave,
My grandson noticed water coming out of the light over the upper bunk. We drained the water out of the light and used a paper towel to help wick the little bit of water out of the ceiling. I believe the leak may be coming from the screws that hold the storage rack on the roof. I want to remove the storage rack and repair the screw holes in the PVC roof.
What would be the correct materials to use to make this repair? I was thinking of putting the screws back into the hole, put a compatible material like a tape over the screws and a sealant all over the tape or similar material used over the screws. Thanks for any advice. —Reggie, 2023 StarCraft, Super Lite Maxx, 19MBH
Dear Reggie,
From what I can find on your 2023 StarCraft, it did not come with a “storage rack” on the roof of the unit as a standard feature. So, it must have been added as an aftermarket item from the dealership or by you or a previous owner.
Why I advise against storage racks on RV roofs
I am not a fan of any type of storage rack or other framework installed on the roof that would allow owners to add additional weight to the roof. The actual weight might not be the problem. However, strapping down items to the racks will cause stress to the rack and ultimately the mounting points while traveling down the road.
Most of these aftermarket racks and ladders are installed with screws mounted to the roof, as you have stated. However, those screws go through the soft PVC material, through the very thin lauan plywood, and into block foam insulation. This does not provide much structure for the screws. It is fine for mounting roof vent covers and even solar panels, as they are covered with a sealant that helps secure the component which is not subjected to the stress of a storage rack.
Here is a cutaway view of a Winnebago roof which has a hard fiberglass upper skin that does provide much more fastening structure than your PVC.
I’m not sure if your rig has a 4” thick construction. Typically, if it has ducted roof air, it will. Otherwise, it’s only 2” thick and you might be chasing a “gremlin” for a long time.
Once you remove the screws and the storage rack, inspect the screw holes. My guess is they will be loose from vibration, especially if you have water penetrating.
Suggestion for repair
Since this is above the bunk bed in the back of the rig, you might be better off using a bolt through the roof and a larger washer with a nut to sandwich the fastening point. Use a flat head bolt with a washer from the inside, and a washer and nut up on the top so it’s not so noticeable inside. I think it would be a good idea to put some butyl tape between the storage rack “feet” or connection point and the roof, as it will help seal the area.
I know some people are big fans of EternaBond tape and then a healthy dose of self-leveling lap sealant. However, I have stopped using EternaBond or any other tape as I have not had much luck with it. Dicor offers a HAPs-Free (hazardous air pollutants) Self-Leveling Sealant that is designed for PVC material. Make sure whatever you use, it is designed for PVC.
Keep in mind that moisture could also be “migrating” from either the side edge or back cap, as well. It would be a good idea to check all the sealant while you are up there.
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DAVE HAS ANSWERED MORE THAN 1,000 readers’ maintenance and repair questions. Read a directory here. There is so much to learn!
Dave Solberg is a leading expert in the RV industry and the author of the “RV Handbook.”
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