The Most Difficult RV Roof Replacement Yet.. Felt-Back TPO

A viewer reached out to me for advice on their 2003 Fleetwood Bounder Roof. They had a membrane roof they had coated and were concerned about some wrinkles and some possible water damage. Although the wrinkles were ugly, there was nothing I recommended doing as the roof seemed to be strong and not leaking. The owner was still concerned about possible water damage and wanted a new roof as they planned on keeping this RV for quite some time.
Unfortunately, I am so backed up I was not able to take on the job, but the guys at Cassone's RV in Mesa, AZ said they would try to help. However, I still did end up helping exclusively, as they were in a bind for time too.
The roof on this RV is Felt/Fleece-back TPO. It is a very strong and durable membrane which is a nightmare to remove easily. Due to the coating that was on it, I could not tell from the photos and we discovered it when it was too late to change out minds..:)
So here is Chad and Micha and myself doing our best to get the job done. Thanks
Roof install kit:
amzn.to/3mfiTie
EPDM roof:
amzn.to/3wmnELt
Cassone's RV
3032 E Main St
Mesa, AZ 85213
cassonesrv.com

[@presenttotheready6365]

We can't thank you enough, you impressed us with your quality work, sorry the old girl put up such a fight. The whole crew is just awesome. Thank you again, Tom & Darcy

[@AZExpert]

Thank you too! I appreciate the confidence and trust. It's really a nice unit!

[@mikes6216]

I've spent hours of my life watching these RV roofing videos. This seems to be one of those oddly satisfying things by the end. It starts out with the mystery of the hidden damage, then the overwhelming size and scope of what you take apart seems like it will be too hard to replace, then the suspect is identified and repaired. Everything is shiny and new in the end, a perfect Hollywood ending every time.

[@AZExpert]

LOL! Thanks! I am glad you enjoy them so much

[@kdub1666]

Nice work guys! That coach now holds the record for the nicest 2003 Bounder roof. :)

[@AZExpert]

thank you

[@22howards]

Brooms are useful! My ex wife uses them for transportation! Great job breathing new life into an older rig.

[@AZExpert]

lol, thank you

[@DavidBrown-fo8qx]

man i love your brain in the rv world you need a tv show and you have a good heart to help god bless you your smart

[@Tony_in_AZ]

Appreciate the time you put in for video... Chad and Micah work well together. That helps a great deal. Thanks

[@AZExpert]

It's always great working with them

[@gregchamberlain8519]

your team did an EXCELLANT job. Congrats.

[@AZExpert]

Thank you very much!

[@stratman50th]

As always James, thanks for posting!

[@AZExpert]

My pleasure!

[@markstench4470]

You guys are true craftsman in your trade , hats off to you and your crew, thank you for educating the masses

[@AZExpert]

thank you

[@6582rg]

The whole time I’ve been watching and listening to your videos I thought the employees were playing ping pong on their breaks. Pickle Ball?

[@AZExpert]

kind of a tennis sized ping pong

[@TheGregWallace]

You are good man for helping those folks out.

[@AZExpert]

thank you

[@ronniecardy]

Good job Chad your a quick learner from the best rv person

[@AZExpert]

I learn from Chad a bunch too

[@philw7174]

Great job. Thanks for the video. Happy trails!

[@AZExpert]

Thanks for watching!! :)

[@702BattleBorn]

Yo AZ E, Thats awesome. Date quoted = date delivered. You and crew are exceptional. Cheers.

[@AZExpert]

Much appreciated!

[@6582rg]

Nice work Chad. I don’t know how your backs hold up to that work.

[@AZExpert]

me either, that's why I let Chad and Micah do it :)

[@davewalters6348]

@@AZExpert 😂

[@mmanut]

GREAT JOB GUYS ‼️ ‼️ Vinny 🇺🇸

[@davewalters6348]

Looks great ! Lots of slow going but excellent outcome. Quite actually I had no idea mtr home roofs were built like this.

[@PaulSter]

Really interesting James. Dang...17+k subs! Way to go!

[@AZExpert]

Thanks!

[@joycebarnett5813]

You guys did a great job. At least working with his own rv, he doesn't have to start over and get all of the new kinks out. Just move on with your own. Thanks for sharing with us. God bless you and your crew. Have a great day. I pray that you all have a wonderful Easter. Stay safe and healthy.

[@AZExpert]

thank you very much!

[@billdennis2993]

AZE thx for sharing an informative and entertaining video watching Chad and Mika work sorry James you were shooting video, looks like a quality job on a well built DP which owner made a good decision to keep. Stay healthy.

[@AZExpert]

thank you. It was a very nice RV inside too

[@ernieb3626]

That thing looks beautiful

[@AZExpert]

Thanks for watching!! :)

[@marlenepineda1079]

it looks fun ripping that TPO roof and tell myself I can do that but then I get frustrated and quit. Nice job. I like your conversations at the end.

[@AZExpert]

Thanks 👍

[@stevebaker8966]

You and Chad are very hard working people

[@AZExpert]

thank you

[@johnb47201]

Awesome rivet Gun!! Maybe some day you will review that rivet gun in great detail. Another great job. Good for them for keeping it another decade or more

[@AZExpert]

It is on my list of things to do.

[@davewalters6348]

@@AZExpert I like the battary powered rivet guns. For years the air powered ones were the thing to have. Now the DC units are the bomb ! 😉

[@anthonygelston4504]

Brill work lads

[@hcrffi]

👍👍 Great job as usual.

[@AZExpert]

I appreciate that

[@floridadog7773]

Nice work 👍😎

[@AZExpert]

Thanks for watching! :)

[@mildredlackey1938]

Well I can sure understand why they want to keep it, very good job guys,

[@AZExpert]

thank you

[@anotherjoe5675]

You guys do great work!... Nice to see it come together for customer... If it was my coach I'd want to replace moulding along the roof radius while I was at it... Just looks kind of crapy to put old painted stuff back up... Probably not enough time, etc... Too bad... You did a nice job!...

[@AZExpert]

Sometimes it saves a great deal of money, time and trying to match paint especially when it's still serviceable

[@CrazyMooseManor]

Great work. You guys truly make it look easy. I can understand why they would not want to buy a new one. New ones are cheaply made, depreciation as soon as you drive it off the lot, taxes, and mortgage interest. So even if they paid $15k-$20k for that roof it would pay for itself within 2 years if that long.

[@AZExpert]

indeed, I think they saved much more than that, I don't know how much this roof cost though

[@SpykersB]

Didn’t know some tpo had felt backing. Good job guys. The owner lucked out! - He should go buy a lotto ticket next, lol. Cheers 🍻

[@AZExpert]

Thanks 👍

[@jzwolak]

Gorgeous!

[@AZExpert]

Thank you! 😊

[@robfl07]

22:11 “Is it a Bounder or Discovery?” “It’s a Boundery”... LOL

[@AZExpert]

Thats a good name for a RV too

[@richardcorcorran8965]

Well done Chad

[@AZExpert]

I'll let him know. Thanks!

[@c.a.mcneil7599]

Thinks for showing process of replacing a roof.

[@AZExpert]

you are welcome

[@michellebarlondsmith6243]

great job

[@AZExpert]

thank you

[@badgerpa9]

Is that Micah Foxworthy, Jeff's son? Good job hope they add the 3 of you to their Christmas gift list. old roof probably would have made it 10 years and now they will hit a tree on the first trip and tear the new roof. Stay safe and healthy.

[@AZExpert]

I think you are correct about the roof. I know the owner was mostly interested in seeing the condition of the deck, but membrane roof can last a long time if properly cared for

[@presenttotheready6365]

I have always been told rubber roofs last 10 to 12 years, ours was 18yrs old. when we bought it in 2010 the original owner had smashed the front air back 4 inches and it "had" a water leak. I fixed the air & leak but could not see under the membrane so i have always had concerns. I would rather be safe than sorry, James and Chad showed me small leaks in other areas... so all in all, better to change it and be good to go until i am not. PS i don't hit trees 30+ years a commercial driver with no accidents. God Bless

[@mikebrand7922]

That's a nice Rivet Gun!

[@AZExpert]

I seem to find reasons to rivet now that I have it

[@torrielandsman4625]

I am really enjoying watching your roof rebuilding videos so thanks for making them. I hope you and yours had a merry Christmas and do have great 2022. The wife and I are looking at an old 37 ft J series Pace Arrow to fix up and am wondering what you think of these older units, I'm just wondering if you think these older units were built well or not? It's a 1992 model. Thanks again for making these videos and may God bless you all.

[@AZExpert]

Be sure to get an inspection but frankly the older units seem to have a quality they just can't or won't duplicate any more. Thanks for watching!

[@anotherjoe5675]

Wow! 1992 Pace Arrow to restore!... Could be a challenge... We own a 38 ft 2001 Winnebago Ultimate Advantage diesel pusher... We've put money into cosmetics, recently a roof restoration and other upgrades over the years including flat panel TVs, digital electronics, etc... But we've decided that we've owned our coach for 12 years, know what it's been through and its problems, etc... I don't care what you buy, old or new you will inherit the problems with that vehicle... They all have them... At least we know where we stand with ours and what remains to be done...

[@sailorjohnboy2325]

Wow that's a lot of prep!

[@AZExpert]

it was, but taking a full day saved 2-3 days of scraping and hopefully a better finished roof.

[@geigeb]

Hi, ! I've been watching a lot of your roof repair videos lately! They are very informative. Where do you buy your roofing materials from?

[@robertburgess6100]

You guys do great work. That was a pain in the ass. And wasn't even doing it.

[@AZExpert]

thank you

[@DennisWintjes2]

Thanks for sharing. Like #6

[@AZExpert]

Thanks for the visit

[@EconomicRefugeesRV]

You're having too much fun !!

[@AZExpert]

thank you

[@scottwall4669]

That roof looked just fine!!! I would have replaced in another 5 years.

[@AZExpert]

yes, I think I said the same thing, the owner wanted piece of mind today for the next ten years.

[@dinosaur6756]

Wow. I've been looking at similar aged motorhomes to purchase and that roof looks FINE. I would be happy to find a roof in that condition. A couple more solar panels and a couple of Battleborn lithium ions seems like a better way to invest the money. I applaud them for keeping it though. Chad, go buy some quality kneepads.

[@AZExpert]

I tell him everyday to wear them.

[@vitalilivits3236]

Thank you for your videos. I really enjoy watching them and learned quite a bit. Is there any particular reason why not to use commercial TPO roof on the RV? It’s a little thicker 0.045 Thank you.

[@hillbillyrv]

Good job Bad Chad and Mika. James, I didn't see you do much except hold the phone. ha ha

[@AZExpert]

I can assure you I helped quite a bit, I was actually replacing another roof for them as they ripped off the TPO...that was not something I had any interest in doing. LOL

[@hillbillyrv]

@@AZExpert I don't blame you. That looked like a job for the younguns. Did you get the box I sent?

[@ericgregory3005]

That felt back looks like the way to go with how well it's glued down. No joy for you but they did it right in 2003.

[@AZExpert]

its a very good product for sure.

[@rnreajr9184]

Maybe you should get one of those long-handled shingle removers and epoxy a heating wire onto the blade. Set the temperature of the blade to 150° or something, and use that to peel the old membrane off. Might be a *little* faster. I would try it myself, but I don't have a membrane roof (or the desire to remove one anytime soon)...

[@AZExpert]

we were trying our best not to damage the thin deck but I'm sure we would have tried something similar if the fire didn't work well

[@KevinCoop1]

I was hoping you were putting a TPO back on so I could find out what kind sealant on top of the side rail. My book says no silicone. Does Chad not know who Bad Chad is? He is on KZbin every day until his show starts again. Chad and Mika did excellent job! Not sure what James did, oh yeh, guidance and teaching. Good job James!

[@AZExpert]

on the gutter rails non-leveling dicor, silicone will stick to TPO just not well at this flex point.

[@KevinCoop1]

@@AZExpert Thank you James!

[@Lakestang99]

I will be replacing a similar TPO roof on a 2001 Fleetwood. Does the Dicor roofing material linked ship rolled or folded? What do you think about the folder kits available on Amazon? What would you suggest when deciding between EPDM and PVC?

[@robertthompson6958]

Dead muppet - funny. Great job Chad and Micah. Great video James. Question: don’t know if this is a disservice to the customers who paid for the work but could you ask them if it’s ok that you let your viewers know the cost and hours of repair. That would be an interesting tidbit for your loyal fan base.

[@AZExpert]

I can ask, I don't know how much they paid either

[@presenttotheready6365]

Hello, i'm the owner. We had been looking to upgrade, an upgrade to us would be a 500k coach buying used for 150 to 200k that being said, even at that price they all have issues. The old Bounder has been an excellent RV with little to no issues and "we know her and maintenance history, she still only has 31k miles on the clock so we choose to keep her and upgrade her systems, interior and roof as most RV's lose their life to water intrusion. The roof cost was well under 10k and well worth not taking a chance covering an unseen issue. We are out of state and choose RV Expert/Cazzones - you all know why.

[@fordracer1415]

So taking time off from the Tiffen or waiting on paint to put the window in. Thanks great video

[@AZExpert]

I had to re-arrange my schedule to help out.

[@InChristalone737]

I hope you guys got some good coinage for all that work

[@AZExpert]

me too, I don't know what they charged on the job

[@Masterk1988]

Boy do I wish my tech would of seen this video before just ripping the tpo off and leaving the felt on the wood 😅... Been a week of getting it off so far

[@natalievrhovnik504]

What type of bonding adhesive did you use for the tpo roof on this project?

[@emtluis]

awesome video BUT ..... i wish you mentioned what materials were used to complete job.. like : glue type, sealeant type, any other stuff used im attempting to repair a rotted roof corner and using your videos for knowleadge and advice,,,

[@AZExpert]

Many of the videos have product links in the discription

[@cwshumate914]

Nice work. Are there really any advantages of the felt vs. regular TPO?

[@AZExpert]

yes, felt/fleece back is much stronger but is more difficult to install

[@FREEHAND.WETGRINDER]

Love your videos. Could you burn off the fleese?

[@andredesouza9767]

Did you replace a roof on a 2003 newmar mountain aire workhorse w22 8.1 yet ? I'm looking for some info? Before start.

[@johnclements8549]

Came out beautiful! Nice work...what would that job cost the customer?

[@AZExpert]

Good question! I didn't quote the job I was just helping so I don't know.

[@johnnarcise6291]

Do you have ant experiences with RV FlexArmor? I am considering it due to the warranty, coating thickness and age of my Monaco (2009). Thank you for your videos I a have already replaced my slide toppers.

[@AZExpert]

Yes I have, it is a good product and works. I don't think it's need on your monaco but it can add some insulation.

[@jannethrodriguez2080]

What would be ideal for a diesel rv roof?

[@addidasnwc]

Won't flex seal or RV armor roof coating work? As a roof option, your thoughts are appreciated , thanks

[@AZExpert]

honestly, this roof was serviceable still and had been coated already. I can't say another coating would stick to that well. The owner wanted to make sure the roof and decking was going to last another decade

[@19Clutch69]

Do you guys go further than AZ? I love work ethic and detail

[@AZExpert]

no I am sorry.

[@Dobbo2958]

I don't want to sound rude. I have no idea of costs with vehicles of this nature. What would the approximate cost of this repair? What about the cost if you had to replace the thin plywood and finally what would the cost of the RV prior to the new roof. Again hope I am not being too personal with your business, it just interests me. All the very best to you and your family...

[@Thesaltymedic36]

Cheaper to keep her. 👍🏼

[@AZExpert]

I think so too

[@TheGregWallace]

Question....Is this pretty much the same rubber membrane type roofing you would find on flat roofs on top of these huge shipping warehouses and if not could you use that type of roof to do what you are doing?

[@AZExpert]

yes, there is a company in Georgia using commercial TPO on RV roof installs.

[@TheGregWallace]

@@AZExpert makes sense.

[@artguerra8748]

What’s your opinion on “lifetime” warranty roofs? Specifically the armor one

[@AZExpert]

How long do you keep your RV? Does the warranty pass to the next owner? Most people only keep their RV a few years

[@artguerra8748]

@@AZExpert well I’m not sure yet I just bought one today with the plan being (like most people) to live in it and travel for 5 years

[@danvalcamlau]

Was that a water based glue??

[@seconddodge]

How much should a quality RV inspection cost?

[@jerryimes867]

I have a 2011 forest river wildcat. 35'. I'm babying the roof. Do you know where I can get a new roof with the quality your crew has? I'm located in southern Ohio. Thankyou

[@AZExpert]

That's rough, no I sure don't---check with the local dealers?

[@KPCKeysDIYBuild-Install-Fix]

Since the old membrane was stuck down so well, could you not have used a liquid EPDM product?

[@AZExpert]

the roof had been coated already but yes

[@cblair0608]

How can I tell if a roof has the felt back by looking at it?

[@AZExpert]

you can't usually Newmar and Fleetwood diesels had it, but I have seen it on 5th wheels too

[@MrThunderbird53]

Hi, what is the chemical you used to clean the felt off the luan

[@AZExpert]

that was paint stripper gel from the home store

[@MrThunderbird53]

Thank you

[@natemaddesyn4550]

How much did this cost?

[@johnwren3976]

Dead Muppets. 🤣 nice Roof was actually firmly attached. Not bad for an old rv.

[@AZExpert]

it was installed very well by Fleewood

[@MililaniJag]

If you're looking for a used 10 yo DP is there a roofing material to avoid? Besides TPO! Thx!

[@AZExpert]

I really like TPO and this membrane was still good. PVC seems to be the best choice right now, it's just been so difficult to track down materials and parts for the last 2 years sometimes choices get made for you

[@MililaniJag]

@@AZExpert Thx!

[@janebray9392]

Micah/Chad/James - The A-Team(Arizona) > they take on jobs regular joes fear to do! The Special Ops Team!👍 Stay tuned for the next episode!!!‼️

[@AZExpert]

thank you!

[@stea2494]

Did that roof really need to be replaced?

[@AZExpert]

I don't think so, but the owner wanted to have piece of mind for the next years

[@robwestley7370]

Sandra Westley from the UK I would have thought by now that they would have come up with a better roof idea over there, we never have this issue over here, our roofs are bonded aluminium. I mean the USA send rockets to the moon and Mars, I would think it’s not difficult to come up with a more water tight option, perhaps as we have such a rainy climate it makes our engineers think outside of the box. 😂😂 it’s just such flimsy stuff you use, it’s like building obsolete roofs before the vehicle is sold.

[@rickc9873]

Did you say a dead Muppet ? Funny !

[@AZExpert]

yes, thank you

[@johnswan9123]

Felt is for roof over roof solutions.

[@johnnarcise6291]

How much would a project like this cost?

[@AZExpert]

I don't know I was just a helper on this job.

[@popsthemachine247]

How much does something like that cost ?

[@AZExpert]

Sorry I don't list pricing on here

[@henrysosebee9241]

What is the price per hlour labor rate

[@AZExpert]

I don't talk about that

[@badasskombucha2193]

I need help with my rv

[@JSMZeez]

What does something like this cost nowadays ?

[@denntamm]

Are you done with the red yet?

[@AZExpert]

spoilers yes

[@denntamm]

Are you going to share it with us?🧐

[@MrJiblack]

I hated putting roofs on, 2nd time I ever done one I almost stepped in the ac hole

[@AZExpert]

I almost die constantly, it keeps things exciting

[@divadyrdnal]

Even looking at this rubber roof that lasted 20 years, think I’ll stay away from rubber roofs... the up front cost savings of this rubber roof cannot justify the savings? We have lots of trees in my area and have had branches skid across my roof more times than I would like, thankfully no damage to my roof... yet!

[@AZExpert]

I am always concerned about ripping too

[@ralphprather8528]

Fleece backed tpo is the worst thing to get off.

[@AZExpert]

It's not my favorite

[@chrisfoxwell4128]

17k, it's only going to get more hectic.

[@AZExpert]

thank you

[@harrystone7539]

What an awful job. I believe my RV roof is also felt backed TPO. Not looking forward to that!

[@AZExpert]

I understand

[@vettepicking]

I might burn off the fuzz with a large torch

[@AZExpert]

we tried, just left melted plastic that had to be scrapped

[@kenj.8897]

Is Chad still your friend ? Lol .

[@AZExpert]

I think so

[@stevest.martin3940]

Yes it’s disappointing Fleetwood uses TPO Still on there Bounders Buy a Tiffin

[@AZExpert]

I agree

[@pault1964]

In the uk health and safety would not be happy no hand rails big no no

[@AZExpert]

Im sure health and safety would have issues with many things I do for sure. There's no much preventative safety oversight here, mostly after the fact.

[@pault1964]

In the uk they changed the law if there is an accident the owners are in court,to many years owners getting away and blaming others,not anymore

[@halfairbank6967]

A chad is not a Karen usually! A Chad is the guy who steals your girl. NOT MY GIRL, because I was always the CHAD. even though my name is not Chad

[@AZExpert]

LOL thats a good point