We had leaks !!!!!!!!!! This was the visual damage and it was slowly getting worse. It was early July 2012. Yes - the blog is out of sequence but the idea of using the blog to record maintenance has been a bit slow to sink in.
Under the distorted vinyl surface there was mould growing - a potential health problem we thought.
We got some industrial cellotape , 50mm wide , and covered the areas of concern.
The marker pen lines were there to check on how quickly it was spreading.
So , we booked Mike and his men at Frontier Motorhomes to do the work. They did the original fit out for us and we were quite comfortable going back for a new ceiling.
First we had to stay some where. Stillwater , just 8km away was the closest camp. Affordable daily rate and it was only for 3 or 4 days - we thought. ( those words again !!! )
A little 1950s , one room unit, clean but uninsulated and with the door and big window facing south.The oil heater was in constant use. Note the nice sunny carpark our towbehind was enjoying.
The kitchen was basic but adequate. The table was one step away and the sofa just one step more . Just like home we thought.
The bed was near new and we used our linen, blankets and pillows.
The shower/loo was just OK.
Our Bessemer oven on a cooktop was ideal .
Cooks every thing , from Bread to cakes to Roast Lamb , vegies and Apricot Chicken casserole.
Mostly on the lowest possible heat setting. Brilliant in the motorhome on gas and doing great service for us here on electricity. But I digress !
In the laundry the prices were old world and so were the coinage. Put in our three 50c pieces only to have them rejected . Over to the Office - "you are using the wrong coins" he said with a grin. Eh ?
The machines still used the Original 50c decimal coins !!!!!!!!!!!! He had little bags of 10 coins available - "will add them to the bill " he said casually.
Now to the workshop . We arrived at morning tea time each day. Day 1 and they had ripped out the ceiling by cutting 100mm away from the walls then applying brute force to remove the two layers of ply. There was wet Batts every where. Multiple leaks there would have to be. But where ?
A really close inspection of the roof provided no clues . We had, over the summer applied 3 coats of good quality roof paint from gutter to gutter. It looked good.
So , outside for a hose test. Mike and Andy had hoses and water going everywhere , I was inside.
Within a few minutes water started appearing , virtually from nowhere. I reached up and pushed the roof up a bit and Hey Presto they could see water squirting out from under a Solar panel mount. Back in the workshop and off came the mount. It had been installed using a Double Sided Tape about 20mm wide placed around the edges , then screwed down with no sealant under the screw head. When raining and the wind blowing on the Solar panels it was flexing the mount and making it act like a diaphragm pump. Pumping water in.
Time to talk . It was no time to cut corners . It would be futile to fit a new ceiling without doing a 100% leak repair - that was easy to agree too . How to achieve the goal - that was the question. It was tough talk . The answer was also tough - take every thing off the roof , reseal all seams , fix the mount screw holes and repaint . Water test . Then and only then remount the gear up there and water test again. Then the new ceiling could be installed . We had the plan but there were still two big questions - How long will it take and how much will it cost ? "Better allow for two weeks work" said Mike & "triple the budget ". Gulp, gulp and gulp again . We were in the classic situation , our motorhome in pieces and the way out was expensive.
The gear came off , even the awning , the collection of bits and pieces was impressive.
Andy got stuck in and by Wednesday ( day three ) it looked OK to start painting the next day.
The paint system chosen was a Marine , 2 pot epoxy , 3 coats , applied at 1 coat a day.
Thursday was wet and cold . Too cold to paint , it needed to be over 10 degrees for the paint mix to react and harden.
Friday was just OK so on went the first coat . It had the weekend to set.
Monday the 2nd coat was applied and on Tuesday the final coat.
On Wednesday morning we had a tough , glossy finish.
The result was very impressive . Money well spent we felt.
Next reinstall all the solar panels and gear.
Out we went for the water test. So far so good . Just as the hose test finished the rain started . This was good , natural rain and wind is a better test than using a hose. It rained for two days !!!!
We waited in our little unit ( which was now on a discounted weekly rate ) and hoped all was well .
It was - we were water tight . Cheers all round and a roof shout after work helped lift our spirits .
Finally able to start work on the original task , the new ceiling .
First the insulation . We had put a lot of research into this , the space between roof and ceiling was 45mm . The batts in this space did not work well . Condensation formed along the steel framing .
We installed a 3 layer insulation sandwich . The coloured rolls are 8mm non absorbent high density compound . This was the first layer , pressed hard up to the roof . Next a thicker layer of closed cell polystyrene followed by another layer of the 8mm compound.
These photos show the coloured 8mm compound and the white areas are the polystyrene
The sublayer of 4mm ply went up next , leaving 55mm clear all round from the walls.
And at last , the new white board , to within 50mm of the walls . The old ceiling had a vinyl finish .
This new board has a tough epoxy finish which is a more pure white and high gloss which reflects the light more and generally lightens the interior .
The Kitchen/Lounge finally back to normal.
The link through to the bedroom.
The bedroom , home sweet home again.
We took the opportunity to upgrade the LED lights so now our tired old eyes can easily read our very depleted bank account statements . Oh well , you can't take it with you as the saying goes.
And here we are , two weeks and three days later , screaming "Let me out of here " - a bad case of cabin fever
Keying in the gate opening number and we were out - it felt like The Great Excape.
Back on the road - happiness ensured.
