REVIVING an old Roof Top AC Cover

GatsbysCruiser

Well-known member
Aug 21, 2005
1,160
30
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50 miles North of Chicago in Waukegan.
With summer coming trips will be planned and some of the AC covers on the roof will have weakened from exposure to UV and weather. You can save that cover.

I was on the roof doing some work, I put my hand on the rear side of the AC cover and it bent down like a piece of paper.
Shocked, I looked closer, the end that curved down for strength was cracked, which allowed the top piece to bend down easily.
I also looked around the base, seeing some cracks near the screws that attached the cover to the base.
I've read and seen stories where the AC cover has just blown off the RV torn to shreds having to be replaced.

If your roof top AC cover has any age on it and it may sit outside in the weather, you need to check it out.

If you find your cover has weakened from the exposure to sun, wind and rain, then I may be able to help you.

you need to carefully remove the attachment screws and lift the cover off.
Be kind of careful at this point as the cover material is sort of fragile from exposure.

I bought some close web fiber glass cloth, mine was actually used for installing those rubber roof coatings, and the cloth is used over seams and where vents and rails attach to the roof.

The key ingredient for this fix is CLEAR TRUCK BOX COATING. I bought a quart size, a couple of brushes and a roller. There will be no saving of any of this after you are done, so , no cleaning.

Cut the cloth into long 1 1/2 inch wide strips, apply some of the clear truck box liner coating along the bottom inside of the cap where the screws attach. you want to go all the way around. run the cloth over where you applied the TBL coating, then dab the TBL coating onto/into the cloth, you want to saturate it.

you want to reinforce the rear top inside of the cap. you don't want to be able to push down on the cover and have it push down like paper.

you may need to put the cover upside down on a table, and put something heavy in it to hold the cover flat, apply the TBL coating, then the cloth as you did the sides.
If you have access, apply to the side top inside corners, front and both sides in front left and right.
You are basically building strength in the form of a frame.
Let dry for 24 hours.

You should have about half a can of the TBL coating left, turn the AC cap right side up, use the roller to apply the TBL on the top and sides. This is to add some strenth and to help protect it from the UV damage. Apply as many coats as your supply of TBL coating has left in the can. You should be able to get at least 2 to 3 coats.

Let it cure.

When you put the cap back up you will notice it is much stronger than it was and a bit heavier. The fit back on the base will be snug, run the screws through the holes that are covered with TBL and attach like normal.

The cover will look like normal, no sign of the reinforcement and will last a lot longer..
 
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