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Old 01-20-2022, 10:53 PM   #1
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Brand: Thor Motor Coach
Model: Chateau 28A
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THOR #25443
A crack in rear top curve

I noticed this area on my roof inspection a few weeks ago and I need some advice on best repair options. I assume this is fiberglass and is the "end cap" I think it's called on the rear of my Chateau close to center of the rear end just below the roof EPDM membrane. It's a large end curve so seems like it might be a little tricky to repair and blend?

Looks like someone might have attempted to cover it with something but it's not at all solid.
Anyone have any thoughts on best repair techniques or is this a pro only kinda thing?
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Old 01-21-2022, 12:21 AM   #2
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THOR #25490
Ok - below is a link that explains why the cracks occur and how to repair. I WILL WARN YOU-ALL. THIS GUY HAS COLORFUL LANGUAGE AND GESTURES. But he is spot on about repairing this type of issue. My suggestion is to have it professionally repaired if you are not a body repair person.

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Old 01-21-2022, 02:19 AM   #3
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Three things come to mind... your budget, your bodywork/painting skill level and your tolerance for "less than perfect".

I used the same products in the (hilariously funny ) video to repair a rusted through Jeep fender... which turned out pretty darn good! Not perfect body shop standards, but good.

That fiberglass "skin" is thin. Mine feels like you could easily put a big dent/crack in it. Yours looks like it was impact damaged??

But anyway... just my 2 worth.
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Old 01-21-2022, 04:30 AM   #4
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Great video and thanks for sharing. I have 7 + decades of fixing things so this seems like just another project to me. More than anything else it's finding the correct products to use. Dynaglass looks like my next purchase with some plastic scrapers and sandpaper. I already have the tools so this looks like a fairly easy job (I hope). It looks like something might have struck the spot maybe a tree limb while backing in to a camp spot. That reminds me....pack a set of tree loppers for our trips.
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Old 01-30-2022, 11:48 PM   #5
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I thought I'd share my results of the roof repair. I decided to use one of the products from the video (Marine Tex) as my crack went completely through the curve and likely leaked. I used a Dremel tool and round sanding bit to open the crack and feather the edges. I used half the White Marine Tex about an ounce. I let it dry two days then sanded and painted with Krylon white plastic primer/paint. I think it came out very well and thanks again for the great advice. Not perfect but certainly close enough!
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Old 01-31-2022, 12:16 AM   #6
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Looks great! Nice job!

P.S. You can make it smooth and glossy by gently wet sanding and then spray/feather a couple coats of clear coat. Plenty of YouTube videos explaining this.

If it has been leaking, you'll probably notice it inside where the curved ceiling cover meets the wall. Just watch for stains or a musty smell. You can remove the inside trim and check that... it's just stapled on.
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Old 01-31-2022, 01:14 AM   #7
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Thanks. I surprised myself too. No stains or smells so maybe i caught it early on. Our rear has upper cabinets over the bed and no signs of stains there. A clear coat would absolutely give a nice finished gloss and I'll look into that too. Nice to be able to do these repairs here at home. Now it's on to the roof and windows. This maintenance stuff seems never ending but I suppose it's keeping me occupied this winter. A few weeks of mild weather has helped too!
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Old 01-31-2022, 10:46 AM   #8
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An RV is a weekend project that just keeps on giving. Great job. Sounds as though you enjoy the challenge as well. Pip! Pip! Cheerio old boy.
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Old 02-01-2022, 04:24 AM   #9
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Weekends? More like weekdays with weekend breaks. My schedule seems to revolve around Amazon deliveries and I decided to concentrate on anything that might leak inside before our next storm cycle hits. Thanks to the knowledge of the members here I have a long list of things to check maintain and repair. Of course it's a labor of love and the prize is a worry free rv trip in comfort not concerns.
Hopefully our experiences here might inspire a few owners to do their own repairs and enjoy the results too.
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Old 02-01-2022, 05:28 PM   #10
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Nice going on the repair! Congrates.
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Old 02-02-2022, 05:30 AM   #11
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The repair looks really good.
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