Re-designing and rebuilding the roof:

bulletAfter 7 months of hard work, spending virtually every single minute of my spare time, I am finally able to pick up where I left off last December: The roof! Now I can see the end of the project in sight.
bulletThe old roof only had a pair of 1X2's down the middle at the top for slope. There was no support on top of the rafters to prevent the roof skin from being caved in when people walk on it. This design flaw is what led to the majority of the leaks. The seal was broken virtually all the way around the roof skin and therefore, water entered everywhere.
bulletThe new design incorporates a flat 19" peak with a 1 7/8" slope down each side for drainage, with solid rafters and no empty spaces for the new roof skin to be dented in..
bulletHere a few pictures of getting the new rafters on.

New Rafters:

The rafters start out as a pile of 2X6.

Rafter layout:

Then I mark out the desired shape.

New rafters cut:

There is the new design - all cut and ready to install.

Before shot:

Time to open it back up and replace the framing.

Out with the old:

Old framing just before removal.

Ventilation:

Hows that for a large roof vent. eat your heart out, Fantastic Fan and Maxx-Air!

Partly replaced:

Some of the new rafters are sitting in place.

Front view:

The whole back is in place - just a few more to go,

Front:

Close up of the front. (Thats my daughter standing in there)
bulletThere's the first batch. Now I better get to work and build some more roof!
bulletStay tuned for more progress shots.

 

bulletWow! - More pictures the night after the last batch! - You probably won't see that again. The roof is coming along so well that I just had to post a few more pics.
bulletThe roof is all framed now complete with openings for 3 vent fans and the A/C. A little more work at the ends will be needed once I figure out how I'm going to put the roof skin over a curved corner with a peaked roof. Hmmmmmmm.

New roof framed:

That was a good days work! All framed up & ready for ceiling panels

Roof framing:

Another shot - Note the slope from the 1X3 runners down to the edge.

Roof framing:

Closer view of the new rafters.

Roof framing:

Low down shot to see the pitch of the roof better.

Fridge vent:

Have to remember to seal this up good inside.

A/C opening:

This ought to hold up the A/C without deflection!

Inside view:

Theres that big open ventilation system again. Hope it never rains again!

   OK ! ! - Sept. 21, 2004 - Time for some more pictures!

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Lets get the rest of the roof framing finished:

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A few inside pictures of the roof framing before the ceiling goes in:

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I did, however, have to redesign part of my roof framing due to an oops on the part of the builder (me!)

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Due to the pitch of the roof as I designed it, the new aluminum skin could not roll over the ends without puckering. I had to reduce the amount of pitch on the ends so that the new skin will lie flat. I have not tried it yet. I hope I have planned it right. If it doesn't work, I will be forced to go to plan B! What is plan B? Don't know - I'll figure it out when I get there!!

Roof framing from inside:

The old galvanized roof covers the framing - you can see the detail better.

More roof framing:

Another shot taken towards the kichen.

Down from the top:

I took lots of pics down from the top, printed them and marked all the measurements of where everything is on the paper for fastening purposes.

Design flaw correction:

I had to gradually slope the roof down to both ends in order to allow the new one piece aluminum roof to curve over the ends without puckering. I initially had the rafters all the same.

Design flaw correction:

Same thing on a different angle - Note how I reduced the pitch of the rafters towards the end of the trailer.

Design flaw correction:

Same correction as the front. I was only able to do one rafter here due to the vent location.

bulletNew ceiling goes in:

First ceiling panel:

Its been a long time coming - but the first ceiling panel is finally in.

First ceiling panel:

Same thing as viewed a little further back.

Installing secong panel:

Heres how I get them in - lift the roof up onto blocks and slide the panel in between the wall and the roof. Cutouts for wires etc. were calculated and done first.

Glueing the panels up:

I used PL Premium panel adhesive to hold the panels in place. From the inside, I used decorative brass colored nails in a grid pattern. The joints are stapled, as they will be covered.

Holding the panel up.

I used a couple pieces of 1X2 as temporary props while I positioned and fastened the panel.

Bathroom ceiling:

You can see the gap while the roof is still up on blocks on top of the walls.

Bedroom ceiling;

This is above the main bed area.

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