Roof Air Only

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While prepping my roof for a tape coat, I removed the covers from the roof air units. They were secured with four sheet metal screws—two at the rear and two at the front.

What I found was concerning: out of the twelve drilled holes in the covers, nine showed stress cracks, and three completely broke apart when I unscrewed them. It was clear that over-torquing and exposure to sun/heat had taken their toll. The last person to work on them (not me!) had used larger pan head screws as a makeshift fix, which only delayed the inevitable. I’ve seen many covers lying by the roadside, and I was close to joining that list.

To fix this, I reinforced all the mounting holes with fiberglass, then redrilled the screw holes, and finished with prep and paint.

Next issue: inside the units, I discovered foam rubber strips that act as ducting for the condenser. Mine were decayed and needed replacement, which I sourced from Lowe’s. A bit of contact cement did the trick, and the new pattern is clearly visible.

Lastly, the package unit itself was filthy. Although the condenser was operational, it was partially clogged with dirt and debris. I used compressed air and a couple of cans of coil cleaner to clean it up. I suspect I was losing efficiency due to the buildup.

I admit these units are a pain to access, but I now believe an annual inspection is essential. I’ll post some pictures soon!

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I faced a similar problem with my AC shrouds. The middle one had significant chunks missing where the screws went through, and someone had added extra screws in different spots, which led to water leaking into the coach. I replaced two of the shrouds with new ones that come with a 30-year guarantee (though I doubt the AC units will last that long!). You can find them at a specific online store.

http://www.icondirect.com/ProductCart/pc/A-C-Shrouds-c3.htm

However, these new shrouds don’t have foam on the underside, and I’m curious about how critical that foam is. Any thoughts?

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I think the foam is quite crucial for a couple of reasons. First, it supports the shroud, preventing it from wobbling, which reduces wear on the mounting screws and helps avoid failure. Second, it seals the condenser, ensuring that air is drawn through it rather than over it.

As mentioned, my seals were rotted, filled with dirt, and crumbled apart. I replaced them with ½-inch foam pipe wrap (available in six-foot lengths). This material has the same dimensions but is much more resistant to dirt, plus the half-inch opening allows for necessary flex. It also has a heat treatment in its compounds.

I reinforced all the areas around the screw holes, including the lip, with fiberglass. Lastly, I painted everything in a matching tone to the bus using single-stage acrylic enamel with hardener.

By the way, you can cut some lengths of that wrap and place them around your wiper blades when storing them, whether inside or out. It’ll keep them fresh and clean for a long time!

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