Total pop-up fabric replacement; Options?

Well it's time to fix up the old Grandby I picked up a couple of months ago. I had decided to try and sell it but kept the idea to fix it up in my head in case it didn't. Well, it didn't sell for what I wanted so now it's time to tear in to it!



It's rained the past 3 days and the old fiberglass insulation and the headliner were soaked pretty much everywhere. I decided to rip it all out and install rigid insulation like I've seen a few folks here do. Check out the condensation / regular ole moisture-from-leaks here:



So this is where I'm at now:



So to get to my real question. At some point I need to do something about the pop-up fabric. It's moldy in some areas. It's got small holes in others. The clear window is so shrunken it barely can touch the velcro. All in all it's not in very good shape. I can't say I'm too surprised since it's 26 years old and there aren't a lot of signs of careful upkeep.

Here's an example of what I mean (yes the shiny wood is from water intrusion):



And the other side:




So... my question is. Right now I see one option: Spend $995 plus shipping to buy the pop-up fabric new from FWC. This seems reasonable, but I have 2 reservations:

1) how difficult is it going to be to install myself; and
2) if I'm going to be making a lot of effort to install it, should I do more work and try and make the pop-up fabric myself from purchased material?

I'm pretty ambitious but I do have lots of other things to be doing. I also have zero experience sewing. It seems beyond a patch job to me. Are there any other options out there for me?

IMHO I would let the pro's do it. They'll get it done right. I know how valuable my time is, and I wouldn't want to take on that task....especially if I had no sewing experience. I'm sure you have addressed this but make sure you solve the leak issues in the roof before doing the upgrade!

I'll be sure to have the roof squared away before updating the fabric. I can be bone-headed but I did think of that one. The roof needs some special attention for sure.

Has anyone ever filled in all the screw holes in the roof and attached it some other way? The new roofs are smooth and use an adhesive, right? Has anyone ever tried using adhesive on the older two-piece roof?

Has anyone ever filled in all the screw holes in the roof and attached it some other way? The new roofs are smooth and use an adhesive, right? Has anyone ever tried using adhesive on the older two-piece roof?


Some folks have backed each screw out a tad, shot good caulk under it and then retightened. By good caulk we're talking 3M 5200. I've also read some folks have used truck bedliner over the top of their roofs, screws and all.

We had the guys at All Terrain Campers replace the side liner material, replace a lift panel, repair the other, reseal the roof, and a couple of other minor items. They did a great job at a very reasonable price, and it was done in a short time. We would highly recommend these guys. It was good to have it done right and we've been happily using the camper ever since.

I sewed and installed this canvas myself. I made it extra tall so I could stand up straight inside (I'm 6'4'). I didn't have the skills to add windows, but it worked out ok without. It's made of heavy cotton canvas and treated with Thompson's Water Seal. Didn't leak when I used it... The guy who bought this camper is living in it right now. The installation is quite easy. It took a few hours. The canvas is sandwiched between the shell and the trim and is attached with ten thousand screws . I sealed the seams with caulk. If you're not a great seamstress, you might save some $$ by buying the canvas premade, and installing it yourself.

I sewed and installed this canvas myself.

Hey, that is impressive. Good work. I do feel like the windows are necessary, though. I guess it's looking like I'm buying the stuff from FWC unless anyone else has a recommendation.

Get a quote from All Terrain Campers for before making that purchase. Everyone else that has compared them vs FWC for the canvas has gone with ATC.

The old canvas might still be usable. I had a 1983 that initially had some black mold.

Since you have nothing to lose and the canvas sides will probably end up in the dumpster, I suggest first try removing the thin nylon inner liner and foam padding.

A new razor worked great around the windows and vertical seams. Removing the upper aluminum trim made it much easier to separate the nylon liner and outer canvas (or vinyl?).

Removing a few screws at a time and working along the top helps to avoid having the whole canvas come loose at once. It's also a good time to reseal under the trim.

After the inside liner is removed, you might find the inside of canvas is relatively clean. There are 2 or 3 RV cleaning products (Camco) which only costs about $5 each at Walmart. It cleans and removes the mold amazingly well, much better than I expected. The exact same product sells for about $15 at the local RV stores.

It took several hours of scrubbing, but it did take most of the black mold and many years of road grim completely off.

For the project, all external screws were replaced with stainless #8 and #10 hex heads ($20 per 100) from Fastenal. I also used their rubber and stainless washers along with a good sealer (Sikaflex 220) under each screw for the roof.







More random photos of the 1983 project: http://www.syncspeedy.com/gallery2/

I have some "before" pics if you are interested.

Enjoy your project.

The old canvas might still be usable. I had 1983 that initially had some black mold.
<snip>
I have some "before" pics if you are interested.


Thanks for suggestion. I'm going to think about that for a few days. I am thinking this fabric is totally shot given how it cracks and crunches from brittleness when I close the top down, though.

I looked through all your pictures. I like seeing similar vintage Grandbys. It's inspiring to see other folks doing what I am planning on doing. I'd love to see the "before" pics if it's not too much trouble.

I agree with 3pin and Ted: Check with the boys at ATC about getting the work done there. Many guys at WtW have gone that route and reported good results.

Your photos suggest you have issues with your lift panels as well. Good luck on your project.

PS: You want windows in the side liner!

Thanks for suggestion. I'm going to think about that for a few days. I am thinking this fabric is totally shot given how it cracks and crunches from brittleness when I close the top down, though.

I looked through all your pictures. I like seeing similar vintage Grandbys. It's inspiring to see other folks doing what I am planning on doing. I'd love to see the "before" pics if it's not too much trouble.

Pics of the 1983 project as it was before the 6 months of rebuilding started:

Whew that does look like it was a project. Actually worse than mine! I've been in contact w/ ATC and it seems my Grandby isn't an '85 after all and is likely mid to late 70's. Hmmph. In any case I plan to at least get it weather-tight and fix up the side-liner. Improvements after that depend upon my motivation and funds.

To bring some closure to this thread:

I visited ATC a couple of Fridays ago. I talked w/ the guys there and got some good advice and ideas from seeing their shop. I ordered a set of corner jacks w/ brackets and a new side-liner. Yeah! I'm expecting that the cost of those 2 things together amounts to more than everything else costs put together (except for my time of course).

I love those guys. Very dependable! Good luck with you install. I'm betting you got some great advice. I am just a tiny bit prejudiced.

We had the guys at All Terrain Campers replace the side liner material, replace a lift panel, repair the other, reseal the roof, and a couple of other minor items. They did a great job at a very reasonable price, and it was done in a short time. We would highly recommend these guys. It was good to have it done right and we've been happily using the camper ever since.



Think you could message me about how you went about that? I know the front lift panel needs replacing- currently its a piece of plywood that is tearing the headliner (more than it already is). My sideliner is nearly new so that isnt an issue. but all the interior paneling other than the sideliner needs work- probably full replacement.

Addie, sorry I don't quite understand your question. We had the guys at ATC replace the front lift panel and they re-braced the rear lift panel. Both work well now, these guys do great work for a fair price. I did replace all the cabinets and some of the interior paneling myself. I bought the materials from ATC. I'd be glad to help with more information.