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Topic: Relining roof/ceiling in Mardon Dalesman

Gords1

07/8/2019 at 10:48pm
Location: Scottish Borders
Outfit: Kip Kompakt 300

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Hi

I am relatively new to caravaning and this is my first post on this site. I recently bought a 1990 Mardon Dalesman 440/5 on eBay in the full knowledge that there had been water ingress from the pop up vent in the centre of the fibre glass roof, affecting the ceiling that was starting to sag and not looking too good. The walls and floor all appear to be sound, so hopefully my restoration will be limited to the roof lining.

So yesterday i took my Stanley knife to the vinyl/foam covered ceiling with some care to expose how bad the damage was. The damp must have happened some years back as all the rotten plywood was dry as was the timber frame. It appears that the pop up vent frame has been resealed as the van is parked on a farm steading and has been subjected to one or two heavy downpours without any leaks.

On inspection the roof frame was not too bad at all. Other than some black staining from the damp, only a few pieces of timber need to be replaced. I am a timber recycler, so have a small supply of seasoned timber that I can rip to the required size. The polystyrene foam insulation is all intact and hand been 'cemented' to the fibre glass roof, but this adhesive had long since failed and it all ended up on my head!

Once the frame has been repaired, I intend covering the frame with 3.6mm hardwood ply and then painting with a quality matt emulsion paint.

I have read as much as I can find on the repair of rotten caravan frames which I think has prepared me to some degree for the task ahead. However, the question that I have for the wise heads in cyber space is as follows.

I can see how the frame has been put together with various fixings including glue and staples. What I have not seen is any evidence that the timber frame has been glued to the fibre glass roof of the caravan? There just seems to be a gap between the top of the frame and the underside of the roof? Is this the way that the van could have been built originally?

Maybe I have misinterpreted what I have read, but it seems that it has always been suggested that the roof frame is glued with grab adhesive to the underside of the fibre glass roof?

Any guidance would be much appreciated by this novice caravan restorer.

Regards
Gordon

-------------
Gordon

chrisn7

08/8/2019 at 1:52pm
Location: West Yorkshire
Outfit: Bessacarr Cameo 625 2011

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I have only done one major repair, but my tips would be to take photos of everything before starting, especially how things are orientated to one another, where holes, wires and fittings are etc. Back this up with paper diagrams with critical measurements.
On dismantling, don't throw anything away until the job is complete, as old parts may still be needed for reference.
In all probability your repair job will be better than the factory!

I nearly bought a Mardon once, but don't remember about the roof. I would guess that is screwed to the roof frame via the awning rails - pull off the trim to reveal the screws.

Good luck with it.

Gords1

09/8/2019 at 4:29pm
Location: Scottish Borders
Outfit: Kip Kompakt 300

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Hi Chris

Thanks for your reply. I have taken photos of the roof as I was stripping the vinyl/sponge lining and made a sketch of the various dimensions. Yes it does appear to be screwed to the awning timber rails. But it does not to have been attached by any means to the fibre glass roof itself.

So I am just seeking some guidance in this regards, especially whether the renovated roof frame should be glued to the roof or left unattached to the fibre glass roof?

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Gordon

chrisn7

11/8/2019 at 10:06pm
Location: West Yorkshire
Outfit: Bessacarr Cameo 625 2011

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I doubt a glue would have been used-almost certainly standard mastic

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