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RV Roof Replacement Using Line-X on a Weekend Warrior Fifth Wheel

rv-roof-replacement-1Ever wonder what it would look like when you tear off the roof of a RV? Hopefully you never have to know. If you do it means you probably had water damage, possible damage from falling tree limbs, or other maintenance concerns. RV roof replacement can be one of the most daunting projects to undertake, especially considering the level of labor and cost. It is more common that we would like to admit given that most RV roofs are not designed with longevity in mind. Water will find its way in eventually. Some times it doesn’t even matter how diligent you are with your maintenance schedule.

Line-X RV Roof Replacement

Most RV owners choose to seal or partially repair their RV roof and avoid replacing it at all costs. A RV’er who goes by onearmyrider at the forums decided to go all in and tear off the roof of his 2006 37′ Weekend Warrior 5th Wheel and a do a full RV roof replacement after discovering significant water and rot damage. After the grueling process of tearing off the roof, he moved on to removing all the low quality insulation. Not surprisingly, only around 50% of the roof was insulated. We assume the factory never expected an owner to tear of the roof to see the poor insulation.


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Then the RV roof replacement got interesting. Once down to the bare minimum, both spray and traditional insulation was installed where needed. Then, plywood was installed over top of the roof structure which added most of the additional weight (total weight of the repair increased the RV 380lbs). Lastly, in an interesting twist, Line-X (yes, the truck bed liner) was used to coat the roof as opposed to the typical rubber roof material. Though unconventional the premise is a good one. Line-X is a rugged weather resistant material that seals permanently locking out dust, dirt, and most importantly water.

The cost for a more traditional rubber roof does vary, but in this case it would have ran more than $5,000. The Line-X coating, which ran from the back of the fifth wheel all the way to front end and over the front, only cost $4,000. Perhaps you could save even more if you used a DIY bed liner kit. When you consider the cost of the typical 2006 fifth wheel, you can see why most folks decide not to do RV roof replacement as it is cost prohibitive. But, in this case, the roof should last for many years without any problems as long as the vents/AC unit are properly sealed and maintained.

Have you done a RV roof replacement? Would you consider Line-X as an option? Please share in the comments below.

18 thoughts on “RV Roof Replacement Using Line-X on a Weekend Warrior Fifth Wheel”

  1. Thor Industries has purchased many Rv manufacturing Companies a list and good info on this company is available on Wikipedia . Very interesting. I Purchased a keystone 2014 and its plagued with shoddy workmanship. Large bubbles on roof are normal??? Rv is at repair for long periods of time waiting for decals. Customer service is a joke . No quality control and mass production i read they have opened up another new plant.. And bought out the company that manufactures their aluminum frames …. Thats scairy. They own Airstream too

  2. I have a 2003 Newmar Dutch Star with a soft roof around the rear a/c. It was well maintained until Nov 2014 when the driver suddenly died. Since, the RV sat under large trees until Jun 2015. I took it to an RV Dealer for service and they discovered the soft roof. After 11,000 mile vacation I discovered it is leaking on the inside. I am 81 years old and driving a 41’3″ RV is to much for me. I need to sell it, but now with the roof problem I am stuck. RV is stored in Leesburg, FL. Looking for some one qualified to do the work or buy it outright and fix it them self. Your helpful comments are appreciated.

  3. Since the tread was initially posted Rhino Lining has me out with Eco Coat which is designed for rv roofs. Check into it. My nearest Eco Coat dealer that applied it is about 60 miles away.

  4. Truck bed liner is not the way to go on a roof. In simple terms, it was not designed for the flex and RV must have in the roof. I had the RV Roof FlexArmor installed on my 5th wheel to protect against water and impact damage. Bed liner will wrinkle and tear. How do I know? After having the RV Roof FlexArmor installed I became an installer, working shows you hear all the creative DIY warriors (like me) who tried and failed with this venture.

    When comparing roofing products please keep these key points in mind:
    . No more caulk, EVER!
    . Sprayed seamless roof system that doesn’t tear, crack, or puncture
    . Applied 3/16″ thick providing 600% elongation with 3500 psi tear strength
    . Transferable “Lifetime No Leak Guarantee” follows the life of the RV
    . All components removed from roof and replaced with new except for the skylights and vent bases,
    . No more streaking from roof materials
    . Any RV roof, any RV type
    . 100% repairable and additional components can be easily installed at minimal cost
    . Proven in the RV industry
    . All work is performed inside away from any elements to guarantee quality results
    . Increased structural strength
    . 100% customer satisfaction

  5. I don’t believe that Forest River is a quality brand of a trailer. I have an SV 160T which I bought earlier this year, and I notice things like how roof fixtures are haphazardly screwed in at weird angles, the rubber roof is trimmed just a little too short to reach the top trim thing in the corner, caulking is done badly, even the alignment of the walls around the fridge is a bit off.

    I would not buy another Forest River product. I know what to watch for in the next trailer I buy, or better yet, I might convert this into a very light-weight tiny house if I can figure out how to do that without adding much weight to it.

  6. we bought a 2014 forest river fith wheel,it has only been 1 month and i notice that the rubber roof is loose at various places (long loose patch across the roof).I was told that these are air bubbles and it is normal.I have been in construction for many years and i know that it is not normal.I only have a year guaranty and i think they are telling me that so that the warranty will expired and i will have to pay for the repair.

  7. I like the job he did and spray on roofing would seem to be a good solution, but I think Line-X is a little brittle for the job once fully cured. I think Rhino, or a variant would be the better choice because of it’s rubbery consistency. I hope the Line-X lasts many years for him though. Great project!

  8. That’s pretty much interesting that the owner removed the roof to check the authenticity of the material and products used. I liked your article.

  9. I have a 1979Pace Arrow that I have to replace the entire roof, inside and out. Any suggestions would be helpful. I got a great deal on this rig, so I can afford to put some time and money into it. I am a carpenter by trade, so the physical aspect is not worrying me.. Thanks

  10. Just a bit of experience with LineX. We used it on two outdoor roof decks 14 years ago. One of the decks that is completely exposed to the elements has cracked and leaked and has been re coated now with another product. Our house painter said that using a good porch paint over the LineX would have prevented this from occurring. The second deck, still in perfect condition, has recently received a coat of paint (it adheres well) and expect it should last for many years.

  11. We did a new roof over Thanksgiving 2013. Wow what a project. We looked into getting it “Rhinoed” or “Linexed” and it was cost prohibitive for us. We replaced a couple small pieces of the wood, then put an entire new second layer of wood before putting an entire new membrane. We luckily were able to do this project indoors (Hubbs workplace) and with access to anything you could possibly need. Including a forklift to haul all the wood up to the roof. This was a job I would not recommend to DIY’ers unless you are willing to do some MAJOR work. This job took a full 4 1/2 days and a ton of physical labor. Came out great, and saved us a bunch of money. We put about $1300 into this, whereas the dealership told us it would be about $7K! We bought this used rig knowing we would need to reroof it, and therefore we got a great deal on it. That’s the biggest job this rig needs, but we do have a few more projects. Good luck to us. : )

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