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Last Updated on October 7, 2024 by Paul Clayton
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RV Roof Replacement: Money Saving Tips
Whether you use your RV for recreation, work, long-term travel, or residence, it can be one of the most important items in your life. Maintaining and in good working order is the top priority for ensuring you get the most out of the money you’ve invested in it. That being said, periodically replacing your roof can be daunting, materially and financially, and it’s not always clear how best to approach this problem.
Key Takeaways:
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- RV Roof Wear and Damage: Over time, RV roofs naturally deteriorate, requiring inspection and eventual repair or replacement. Ignoring this can lead to more severe damage.
- Replacement Materials: The article highlights the options for rubber roofs (TPO, EPDM, vinyl) and mentions more durable materials like aluminum and fiberglass. Rubber roofs, while more common, require more frequent care.
- Cost Considerations: Hiring a professional for a roof replacement typically costs $3,000–$6,000, while a DIY job can be around $1,000–$1,500 for materials, potentially saving money but requiring significant effort and skill.
- Tools and Materials: Key tools include a power drill, utility knife, screws, and broom. Materials range from roofing sheets and adhesives to seam tape and caulking. Having a partner to assist can be crucial for some tasks.
- DIY Challenges: This project involves significant safety risks, technical skills, and potentially discovering unforeseen damage, such as rotting plywood, which may increase costs or labor.
- Step-by-Step Process: The process involves removing old materials, assessing the underlying structure, cleaning, applying adhesive, and carefully installing the new roof material, ensuring no air bubbles and a tight fit.
You should expect your RV roof to wear out and become damaged over time, even if no specific events cause significant damage all at once. Every so often, you must inspect your roof and gauge its current level of wear. When the outer material begins flaking off, you must repair or replace it immediately to prevent more significant damage down the road.
This article will discuss many questions you’ll want to answer before you begin this process. We’ll give you an overview of what a replacement might look like if you do it yourself. After reading, you can decide whether to take this project on or hire a professional to handle the task.
RV Roof Replacement Materials
This video has been included to clarify the topic. Credit goes to AZ Expert
Before proceeding, let’s establish exactly which roofs we’re discussing. Today, we’ll examine options for rubber roof systems, including TPO and EPDM systems and any vinyl system you might be working with.
Your roof could be covered in aluminum or fiberglass. If that’s the case, congratulations! These materials wear out much less quickly than the more common rubber roofs. However, just because they’re more durable does not mean these roofs never have damage or need repair. You must inspect your roof frequently and be ready to repair or replace any damage you notice.
For those who do have rubber roofs, keep reading. We’ll discuss all your replacement options, including the best roof coatings.
Financial Concerns
When you notice damage to your roof, whether it’s routine degeneration or acute damage, you’ll first need to decide whether to do a full replacement or a simple repair job. The financial implications are significant, with repairs being much less expensive than replacement.
If you’re confident that damage is limited to one small part of your roof, repair kits can be purchased for as little as $20, and they will do a pretty good job of patching up the roof. RVpartscountry.com has a wide selection of repair membranes that come with their sealants and are easy to install on your own. Of course, you can enlist a professional for this small job, and in that case, you’ll be paying for labor in addition to the parts, significantly increasing the cost.
To be sure, you’re looking at a much greater total cost for a replacement. Of course, quotes among professionals in your area will vary, but generally, you’ll be looking at $3,000 to $6,000 in total cost if you hire someone else to replace your roof. This number will change to account for the size of your roof, its exact material, and any special considerations, like any additional damage that may have occurred before the replacement.
That number might seem steep, and it’s worth considering that the single biggest 
line item on your bill will be the labor of the professional you hire. That means taking on this project yourself could save you significant money. We’ll get deeper into the tools and materials you need shortly. Still, generally speaking, we’d expect folks with a well-stocked toolkit to spend about $1,000 to $1,500 on parts if they want to do this project independently.
Before you go down the DIY route, know this is not a project for beginners. The tasks to complete a replacement are challenging, and some are dangerous, given that you’ll be up on the roof of your vehicle while working. If this work is done poorly, you can cause more damage to your roof quite easily, and that’s nothing to sniff at.
Working with a professional can save time and a lot of hassle, but it comes at a significant expense. Let’s explore deeper what this project will entail if you decide to go it alone.
Tools
If you already have a well-stocked toolkit, you probably have most of what you need for this project. But let’s take a look at precisely what we’ll need. Generally speaking, you’ll want to have:
- Power drill
- Putty knife
- Utility knife
- Screws or bolts for replacing every part holding your roof down
- A push broom or other implement for smoothing bubbles out of your roof material
- Foam gun
- Caulking gun
- Paint roller (to be used for rolling on adhesive)
- Rags
I mentioned here that you’d want replacement fasteners for anything you pull out of your roof during this process. This is an essential item to remember. You’ll end up unscrewing quite a bit of stuff from your roof as you replace it, and you should always check to see how much rust has accumulated on the screws you pull out. Anything that’s gotten too damaged should itself be replaced.
Another useful tool is a friend to help out. Depending on the exact size and shape of your roof, some tasks in this process will be impossible to complete independently. This might not be your best task if you don’t have reliable access to a second pair of hands.
Finally, as you review this list, please remember that we’re talking about the general outline of how this project usually goes. During your repair, you can quickly uncover significant damage that was not apparent before, which may require specialized tools and equipment.
Materials
The single biggest cost of materials will be the replacement roofing material itself. This will cost $250 or more, depending on the type you go with and the size of your roof. Keep in mind that you can use any of the rubber material options, TPO, EPDM, or a vinyl sheet, on your roof. Make a decision based on cost and what you think will work best.
These replacement sheets will usually come in rolls that are wide and long enough to cover your roof and hang past your end caps/retaining bars. Keep that overhang in mind when picking one out—if it only barely covers the top surface of the roof, it won’t do the trick.
You can usually buy this material in a kit that includes a compatible adhesive for installation. Make sure you understand what comes with the product you buy. If this adhesive is not included, you must purchase it separately.
Beyond this key piece, you’ll also want to have on hand:
- Seam tape
- Mineral Spirits
- Sealing putty or caulk for all roof fixtures
- Replacement retaining bars or caps, if desired
- Sealing tape for your retaining bars
This can be purchased from any online RV parts retailer you like.
When considering materials, again, you’ll want to consider that the replacement process might uncover additional damage, which will also need to be repaired. Most commonly, this will entail replacing the plywood and Styrofoam that make up the inside of your roof. Keep those potential costs in mind before embarking on this project.
If you can procure these materials and tools, you’re ready to begin the replacement process. Let’s examine exactly what that process entails.
General safety tips
As we proceed, please ensure your safety while working on your roof. While it’s not as high up as most building roofs, your work here will still take you high enough into the air to cause some damage if you fall. Be careful and take your time. While your roof should be strong enough to hold your weight, a significantly damaged roof might not hold up as well as expected.
One major hazard will be the holes in your roof for ducts and other fixtures. Be sure you know exactly where these are before you start, and be careful not to step in them accidentally.
Getting started
Once you have gathered all your tools and materials, you’ll begin the replacement process by clearing out any hoods, racks, or other fixtures attached to your roof’s top. Even if you suspect you can work around a certain fixture, it’s best to remove it before taking any other steps.
Most of the fixtures on your roof should screw on and off. Remember to inspect each screw or bolt to see if it needs to be replaced with a new one at the end of the process. If any items are riveted onto your roof, you’ll need to drill out those rivets and remove the item that way.
Once the roof is clear of all fixtures, you can release the roofing material by unscrewing and removing the retaining bar and any caps on the other sides. These materials should also be inspected as they are being removed to decide which, if any, will need to be replaced. With all these items, including the roof fixtures, you may need to scrape away the old RV caulk previously used to seal their seams to locate all the screws holding them in place.
Once the roof is free from everything that had been screwed in place previously, you’ll need first to scrape off all the caulk that had been placed on there during the last installation. After that’s all clear, you’ll be ready to remove the old roof.
This process is quite simple. You’ll use a putty knife or other thin instrument to slowly pry the old rubber off the plywood or other material beneath it. You will remove the entire sheet of rubber, so be sure to scrape off every little piece. You’ll want a bin or other receptacle ready on the ground level to accept these discarded pieces as you pull them up.
When you remove the old roof, you should see only the underlying material exposed. (As mentioned, that material will likely be plywood but could also be some manufactured material.)
Assessing roof integrity
Now that the inside of your roof is exposed, it’s time to look for further damage and determine your next steps. Start by looking at all the exposed plywood. If there are any areas where the wood is crumbling or otherwise falling off, that section will have to be removed.
Your roof is likely constructed using the sandwich method, with two layers of wood surrounding a Styrofoam core. These instructions assume that or a similar construction. If you’re unsure of the construction, it’s worth checking your owner’s manual beforehand.
Replacing damaged plywood is not a complex process. You’ll use a jigsaw to remove damaged areas and expose the foam below. Inspect this foam as well. Some scraping or damage from your work is acceptable. Still, if the foam has deteriorated significantly, you may need to work on replacing it as well, which will, unfortunately, be a much bigger project.
As long as everything is structurally sound, you can replace the plywood by cutting yourself a new piece of identical size to the one removed. Apply the patch by first using a strong wood adhesive between the foam and the new piece and then by screwing the board in place.
If you replace any sections of this surface, place seam tape over any new seams formed to ensure your final roof will be nice and smooth.
Cleaning and preparing for the new roof
Before proceeding, it’s critical that you thoroughly clean the roof surface to ensure strong bonding for the adhesive you’ll use next. First, go through several preliminary passes with just rags and water to remove any large pieces of debris still on there. Then, take your mineral spirits and use those for a deep clean to ensure everything is nice and smooth.
Applying your new roof
The application process is complicated and will take significant time. Before beginning, read the materials provided with the specific roof you’re using to see if the manufacturer requires any unique steps.
Generally speaking, you’ll want to place your roll on the roof and then begin applying adhesive one section at a time before unrolling the roof over it. When you use the adhesive, please wait a few minutes until it becomes tacky before unrolling the roof over it. This will prevent the adhesive from pooling up and running places you don’t want it to go.
You’ll need to cover the entire roof surface slowly in this fashion and then double back to spread adhesive under the section where the roll had been sitting initially.
This process is easiest in warm weather, as the roof material will be more pliable and make for a smoother application. Make sure to square the roll as best you can before starting so you won’t find yourself rolling straight off the side as you go.
After each roof section is rolled on, take your broom and smooth out any formed air bubbles. You’ll do this a little bit each time you roll out some more cover, and then once it’s all out, you’ll spend a good chunk of time reviewing your work and making sure no new bubbles form. This is a crucial step, so take your time and look closely to catch even small bubbles before the adhesive sets.
Once everything has dried, you’ll be left with roof material covering your roof and hanging off of each side. Pull the roof taut and then re-install your retaining caps on each side. Add sealing strips underneath these caps before applying, and seal them on the fixture if necessary. With the caps securely in place, you can take your knife and carefully cut off any excess that hangs under the cap.
Wrapping up
The last step is to reinstall your roof hoods and fixtures. For large holes, it’s best to take your time and carefully recreate the hole after the roof adhesive has dried.
I like to mark out the area above the hole and begin by drilling into the four corners where my gap will be. Then, take your knife and make two cuts from corner to corner, crossing over the center point. You’ll be left with four flaps hanging down. Take each one and secure it by screwing it into the plywood underneath, then cutting off any excess. This will leave you with a hole that does not compromise the roof’s integrity.
With everything in place, you can replace your hoods and other fixtures by putting them back on. Be sure to pre-drill any new screws to avoid splitting the plywood underneath.
Once all your items are back in place, you can apply the sealing caulk to any gaps between a fixture and the roof. This is an important step, so ensure each gap is covered and left watertight.
Bringing it all together
If you feel confident taking all the steps required for a replacement, doing this project alone might be a good option. Doing so could save you hundreds of dollars in labor costs, and if your work is done correctly, you’ll be left with a roof that will last just as long.
That said, don’t feel too bad if you don’t consider this project within your grasp. One option is to look around for a friend or acquaintance who has more experience with this kind of project and might be willing to work with you to get it done. Even if you end up paying some money to get this kind of help, it’ll be well worth learning the process for your next replacement.
It is very important to keep track of your roof’s status. Be sure to get up and check on the top of your RV often, and don’t hesitate to repair small issues before they become big ones. If maintained well, your roof will serve you for years to come.
RV Roof Replacement FAQ
What is the best material to use for my roof?
There are three main options for rubber roofs: TPO, EPDM, and vinyl. All three are quite viable. In general, TPO is a bit cheaper but doesn’t last as long. If you have the budget, EPDM or vinyl will give you the most staying power, provided they’re properly applied.
When should I replace my roof?
I wouldn’t keep a roof membrane around for more than two or three years, even if you don’t notice any damage. If you notice damage to the roof membrane itself, you’ll want to repair it immediately and replace it if the damage is widespread. If your membrane becomes brittle and flaky, it’s time for a replacement.
Will replacing my roof affect my warranty
It’s entirely possible that replacing your roof yourself will affect any warranty over the rest of your vehicle. You should always consult your warranty before doing significant repairs to see if that’s the case.
What do I do about water damage to the inner layers of my roof?
If you find yourself in this situation, assessing the damage and replacing any waterlogged or damaged layer is essential. If water seeps as far as the interior cabin, you can repair that side by removing and replacing the affected area.
How can I care for my roof to make it last as long as possible?
You can take several steps to extend the life of your roof membrane. Most take common sense: avoid situations where branches or other debris will fall and damage your roof, keep it under cover when not in use, etc. Beyond that, you can and should use a cover for your RV for an extended period when it’s not being driven. Keep the body clean and avoid any buildup that could cause problems later.
Final Thoughts
RV Roof Replacement: Money-saving Tips are essential for anyone looking to maintain their vehicle cost-effectively. An RV is a significant investment, and its upkeep requires consistent attention, including the roof, which is often exposed to harsh weather conditions. However, there are several ways to save money on RV roof replacement.
Firstly, regular maintenance and inspection can prevent minor issues from escalating into more complex and costly problems. By addressing potential problems early, you can significantly reduce the overall costs of RV roof replacement. Secondly, doing some tasks yourself instead of hiring professionals can also help you save money.
Simple tasks such as cleaning and applying protective coating can be done without professional help.
Lastly, choosing high-quality materials for your RV roof replacement can be a real money saver in the long run. While they might cost more upfront, they are more durable and require less frequent replacement, saving money over time. Investing in a good quality sealant can also prevent leaks, reducing the need for frequent repairs or replacement.
In conclusion, RV Roof Replacement: Money Saving Tips is all about being proactive, doing regular maintenance, considering DIY options, and investing in high-quality materials. These strategies not only help maintain the condition of your RV but also ensure your wallet stays healthy.
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