I'm just wondering if anyone has run into this problem before. We just arrived in the beautiful [and very cold] shores of Lake Eufaula, in Eufaula, Oklahoma. It is cold and going to freeze tonight so I didn't hook up any outside hoses [water or sewer]. As I was finishing setting the Hi-Lo up, I noticed something that was not there before. A crack has developed on the rear shroud covering of our Hi-Lo. When we awoke this morning it was raining and I arose and did my normal bathroom thing, a drop of water hit me on my head. It was coming from the vent above the toilet. I pulled at the edge of the interior frame, and a considerable amount of water leaked into the bathroom. It eventually stopped and I thought it must be because of the high winds and rain we experienced all night.

After arriving in our new campsite today and as I was seting up this afternoon, I looked up at the back of our 2406 Towlite and I saw a crack in the back shroud that I had not noticed this morning. We had traveled some back highways in Oklahoma and they were pretty rough but not anything that I thought could have caused this. My wife, Carol, said it must have happened last Saturday when we had the RV detailed and the guy was on top of the RV cleaning the black off the roof. Maybe so, but I think I would have noticed it at the time. The man who was on the roof weighed only 160 pounds which should have been okay at that weight.

Anyway, there is a crack that has develeoped n the rear cover just over the running ight lens and I can clearly see daylight through it.

Aside from the obvious, that is, I must make some quick temporary repairs with some caulking, I'm wondering if anyone else has had this problem, and.. what is the suggested fix?

I appreciate any suggestions.

Jerry & Carol Curtis Fredericksburg, TX
2406 T Towlite F250 4x4 7.3 Diesel

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Jerry, as far as a temporary repair, you can go to any hardware store (maybe even Wal Mart) and buy a roll of aluminum faced tape. This tape is mainly used for air conditioning duct work. Clean the area thoroughly with alcohol, let it dry and apply a strip of the tape over the crack, then apply an additional strip of the tape just off center of the crack, this should provide a sufficient patch unless you get into a severe thunderstorm. As far as a permanent, I would check with a reputable fiberglass repair shop (boat repair), they should be able to make this repair for you. It is very possible that the crack occurred because of a rapid drastic drop in temperature which may have caused the plastic shroud to shrink unevenly.

Hope this helps, Richard and Barbara

2003 27' Towlite
2002 F150 5.4 Super Crew
ror007@aol.com

Thanks Richard,

I did come prepared for anything [I have a roll of Duct Tape in my tool box] LOL.. I have some of that tape you described but it is 600 miles away in my work shio. I am hoping to be able to borrow a tall ladder so that I can get some duct tape on it tomorrow before the rain really sets in. If not, I did bring a shorter step stool but it is co cold I just didn't want to have to suck in the slide out and let all the heat out.

Yes, I would think a professional should be able to repair it and hopefully do a match on the colors so it won't look too bad.

I am thinking I should remove the frame around the vent and possibly place some heat and a fan on it to prevent roof and interior deterioration. WE both have family here so I should be able to borrow some tools and make some temporary repairs.

I appreciate your help, Richard.

Jerry

Sorry to hear about your cracked shroud. I think it would be worthwhile to stop at walmart and get a roll of aluminum tape. Thay cary Ductbrand tape(silver) that would be great for this temp. repair. Costs about five dollar. You also might consider a close by RV place that sells Externabond tape. Get externabond tape even if you have to pay for expediated shipping for where you are. I don't think the guy up on your roof did this dammage. The fiberglasses flexes a lot as you bounce down the road. Get this covered up today. Use a folded cheap shower liner if you have to. Prevent any further water intrusion. We developed a serious propane leak on the inside of our stove(cracked fitting). Our can of plumming putty was at home. Had to purchase one anyway. I think I will purchase a small roll of externabond tape for emergency repairs. Just remembered JB Weld it comes in a tube in the automotive section at Walmart or any hardware store. A great product to have on hand. Hope these ideas help. Your trailer will defeniately be fixable by a professional fiberglass body person. Boat shops seem to be the best.

Cracks in the front and rear end caps were epidemic when Hilo changed the plastic material in their caps in (I think) early 2000's. This is a well known problem.

We replaced the rear end cap, and took off and patched the front, of our 2005 27' Hilo. The cracks will get worse, and they magically appear - probably not the result of anyone walking on the roof.

You can get some of the cracks repaired by plastic welding - check our local RV dealer, maybe they know.

If you take the end caps off, you can reinforce the inside with fiberglass cloth and epoxy like we did on the front cap. Let me know if you are going this route - I took extensive pics of the 'operation'.

Good luck!

Jerry, you mentioned using regular duct tape, this probably not a good idea, duct tape doesn't like either water or cold temperature. If aluminum duct tape isn't available you might consider using a good grade of silicone bathtub seal.

Had to leave and get my daughter from Target(seasonal job). Hubby said your end cap is made out of plastic. I was going to look up old posts because I seem to have a recolection of this problem. He also said to use caulk to temporarily fix the problem. WallMart carries bondo.ect. for this type of repair. I would be really mad at HiLo for changing to inferior parts and still charging top doller for new units. Tried and true stands the test of time. Glad to have others that have done this repair advise you.

I'd also try to get to the end of that stress crack and drill a small "stop" hole there to keep it from extending further!

- Jack

__________________
Hi-Lo 1707T
2005 F150 4x4 KR SCrew

Jack & Janet,

I went to the local end cap repair shop [Wal-Mart, LOL] and purchased a roll of weatherproof/waterproof aluminum tape and cut it the 10-1/2" length of the split and made temporary repairs. There was no need to place a 'stop hole' as it began at the very top and stopped right at the right lens cover of the running lights. While on the ladder, I did notice that it appeared that almost every other screw hole, that holds the end cap in place, had mini-splits beginning to appear. There were even two mini stresses that were not associated with a screw hole!

I'm thinking that I should follow the advice of Reno and remove the shroud [cap] and use a fiber glass cloth and epoxy and strengthen the underside of the cap possibly all around the full measure of the circumference to prevent future such events. Or, as I recall reading a post a while back of an older Hi-Lo that was being scrapped, I'm wondering since it was pre-2000 if it was made of the stronger material and if they are all the same size? If so, I should consider seeing if he is willing to take the cap off and sell it to me and replace this shoddy, cheap plastic material that Hi-Lo used?

I hope the new Hi-Lo owner is paying attention to these posts. The material got weaker and the cost still went up! Something is wrong here.

Thanks for everyone's input.

Jerry & Carol Curtis
2406T Towlite Ford F-250 4x4 Diesel

Beginning with the 2010 models the end caps were made of fiberglass. Whether this will be continued is yet to be seen.

ABS was used on Coleman popup roofs and they had many problems with stress cracking. The repair was much the same as with the HiLo, drill holes at the ends of the cracks and seal the cracks with a flexible sealant.

I have a question as to how fiberglass repair will work on the ABS material, will it stick?

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Great Wife, Joyce
2010 2310H Hi-Lo
2012 F150 4X4 SuperCrew EcoBoost w/Leer Cap
Reese WD Strait-Line Hitch
Amateur Radio K3EXU