Clever Travel Trailer Water Damage Repair Saves Thousands
Last month, I shared the extensive water damage that had sidelined a 2007 Thor Adirondack 31BH travel trailer our family has owned since 2016. The situation looked severe due to years of water ingress from a faulty roof seal, leading to floors so compromised they could break and walls so rotted they were easily peeled away. A complete replacement of damaged sections was estimated at a prohibitive $25,000 or more. However, an RV dealership devised a strategy to tackle the issue for a mere $7,800. Here’s the ingenious method an RV dealer employed to fix our travel trailer’s severe water damage.
When our family travels, we typically use a travel trailer, opting to stay at campgrounds instead of hotels. Our road trips have spanned numerous locations across America, from Ohio to Florida. We appreciate the comfort of bringing a semblance of home with us on the road, and honestly, we prefer most campgrounds over hotel stays. The simple pleasure of grilling and enjoying a campfire as the sun sets is often unbeatable.
Despite owning two substantial travel trailers, our family hadn’t used one for camping this year. My own recent overnight stays have been limited to my Volkswagen Touareg or a tent. This past summer, my parents acquired a new Heartland Mallard M33. Yet, we’ve been unable to take it on a single trip because each attempt was thwarted by a significant mechanical failure.
RV interior with table and seating area
Most recently, during a planned test run, the water heater developed a massive leak. Due to ongoing parts shortages, the camper remained inoperable for the entire season, awaiting necessary components. This series of issues led my parents back to considering the trailer the new Mallard was meant to replace, the 2007 Thor Adirondack 31BH. This particular travel trailer weighs 6,256 pounds and measures approximately 36 feet in length. Reviewing the original sales documents revealed they paid $9,000 for it, correcting my previous recollection where I may have confused the price with that of a used Ford Expedition they purchased.
Upon picking up the trailer in 2016, I immediately noticed classic signs of water damage: bubbling on the exterior skin.
The Severity of the Travel Trailer Water Damage
Close-up of bubbling fiberglass exterior on a travel trailer
For a quick overview, the walls of most travel trailers are constructed using a vacuum-bonded “sandwich” technique. This involves an exterior fiberglass layer bonded with two layers of wood and styrofoam, with the interior wall panel forming the other side. The wood layers are often thin lauan, a type of tropical plywood.
Initially, things seemed manageable. The floor near the rear felt slightly soft but remained solid, and the exterior bubbling wasn’t severe. The dealership where we bought the camper (different from the repair dealer) dismissed the bubbling as normal and not a concern. However, my parents unfortunately learned that ignoring such bubbling signs is a costly mistake when dealing with potential travel trailer water damage.
Worsening bubbling and delamination on a travel trailer exterior wall
Over time, the bubbles grew larger, and the floor continued to soften. By 2020, I stepped into the camper and felt the floor give way beneath my feet. The exterior appearance near the bathroom area looked as if it had been in a minor collision. It became evident that the damage had significantly worsened.
My parents were hesitant about what to do next, leaving the trailer unused. This year, they decided to face the problem and get it fixed. Two additional years of water leaks inflicted heavy damage, resulting in the exterior skin literally peeling away from the trailer structure and the floors splintering badly.
Severely delaminated and peeling exterior wall of a travel trailer
As explained by the dealership, travel trailer water damage repair is often necessary due to failed seam seals or other types of damage that expose the internal luan layers to moisture. The damage progresses slowly, beginning with saturation and cracking within the luan layers hidden behind the fiberglass siding, making it invisible initially. Subsequently, delamination occurs. As these materials degrade, they separate, leading to the visible bubbles on the surface. The dealership emphasized that by the time delamination is visible, the underlying damage has likely been developing for months, if not years. It’s crucial to recognize the signs early, just as anyone researching the best 4 season travel trailers considers construction quality.
The dealership also noted that not all delamination necessarily stems from water damage. In some cases, delamination can occur simply due to manufacturing defects or general wear and tear causing the luan “sandwich” structure to fail over time.
Closeup of fiberglass delamination bubbles near a travel trailer bathroom
Regarding the Adirondack, bubbling was apparent in two main areas: the front wall and the walls surrounding the bathroom. The bubbling near the bathroom was so pronounced that you could visually identify the bathroom’s perimeter based solely on the pattern of the damage.
How the Dealer Approached Travel Trailer Water Damage Repair
The camper spent several months in the dealership’s repair bay, and during this time, we gained significant insight into the problem. Technicians pinpointed the source of the leak to the plastic skylight positioned above the shower. This skylight serves to provide natural light and a few extra inches of headroom, particularly useful for taller individuals. Regrettably, the seals around this skylight had failed years prior. Consequently, with every rainfall, water infiltrated through the skylight, saturating the surrounding luan walls and floor. This repeated process over years caused extensive damage, even though the bathroom area initially appeared fine on the surface.
Shower skylight from below inside a travel trailer
Fortunately, the technician believed the damage to the front of the trailer was less severe. Their inspection indicated that the outer fiberglass siding had delaminated in that area, but the layers beneath remained largely undamaged. This suggests the front delamination was more likely a manufacturing defect rather than a result of water ingress, potentially saving significant repair work. My parents inquired about the cost to fix all the damage and were presented with a couple of distinct repair options. Comparing repair options is something owners of diverse models, from modern units to those exploring 1976 prowler travel trailer floor plans, eventually face.
To fully rectify the extensive damage in the rear section, the dealership explained it would require removing the entire rear floor. This undertaking would necessitate dismantling and then completely rebuilding the trailer’s rear structure. Similarly, fixing the wall damage would involve tearing down and reconstructing that section as well. The estimated cost for this comprehensive restoration exceeded $25,000, and that figure didn’t account for any unforeseen complications or additional hidden damage discovered during the process. Moreover, this estimate did not include the cost of repairing the front wall delamination.
Interior view of a travel trailer during water damage repair, showing sections of subfloor removed
This illustrates why water damage can be so devastatingly expensive to repair. By the time the damage becomes overtly visible, the cost to restore it can easily reach five figures. However, the dealership proposed an alternative approach: essentially a sophisticated “patch job.” This method offered a dramatically lower cost estimate: $700 for the wall repairs and $7,100 for the floor, totaling $7,800. Considering the significant difference, this cheaper option became the focus for the necessary travel trailer water damage repair.
As the technician detailed the process, they first carefully cut out the visibly damaged sections of the wall and removed the compromised vinyl flooring from the affected areas of the floor. The camper was then left in the service bay to dry out thoroughly using a dehumidifier and absorbent agents to draw out moisture. Once completely dry, the technicians applied a sealant to the existing subfloor layers and then installed a new layer of plywood directly on top in the damaged sections.
Technician applying sealant to travel trailer subfloor during repair
The repair team subsequently installed new vinyl flooring over the repaired subfloor areas. The camper’s existing carpet was put back into the rear bedroom section. Certain fixtures were then reinstalled, raised slightly (just under an inch) to accommodate the new plywood layer on the floor. A metal transition strip was added between the original center floor section and the newly raised rear section to mitigate a potential tripping hazard caused by the roughly one-inch height difference. This pragmatic approach is valuable insight, whether evaluating older models or newer ones like the best 4 season travel trailer for full time living.
During the repair process, it was also discovered that the shower unit itself was a significant contributor to the water damage, as its seals had also failed. This meant that every shower taken in the trailer had potentially worsened the situation. Addressing this required removing the shower unit for cleanup of the surrounding walls before reinstalling and properly sealing it.
The repair team was able to salvage and reuse some sections of the original flooring materials, but a considerable amount had to be discarded. Here’s a look at what was removed and tossed out:
Discarded travel trailer flooring materials showing mold and rust residue
This pile consists of residue from rusted fittings and a significant amount of mold. While none of our family members became sick, the presence of mold for an unknown duration is concerning. (Note: The technician initially referred to this material as linoleum, but a reader correctly pointed out it is most likely vinyl flooring.)
On the exterior, the rotted plywood sections were replaced with new plywood before being sealed. This “patch job” doesn’t rectify the delamination itself in the traditional sense. Instead, it employs external braces and self-tapping screws to secure the delaminated fiberglass layer back onto the trailer structure, preventing it from peeling further.
Exterior view of travel trailer wall repair showing screws securing delaminated panel
Different angle of exterior travel trailer wall repair with securing screws
The technician acknowledged that the exterior repair might not look aesthetically perfect, but expressed confidence that the primary water leaks have been sealed, and thus, the repairs should provide longevity and prevent further internal damage. This practical solution is the kind of detail travelers appreciate, perhaps even more than stunning photos like those found at flying j dealer — mega travel plaza breezewood photos.
Touring the camper for the first time since the completion of the travel trailer water damage repair, the interior feels significantly improved. The floor in the rear now feels just as solid as the front section. The rear bedroom, which is “my bedroom,” looks as inviting as it did back in 2016. Notably, the bathroom area feels more solid than it ever did, even when we initially purchased the trailer.
Cozy interior view of the repaired rear bedroom in the travel trailer
I assisted my parents in towing the repaired trailer to its winter storage location. Two outstanding issues remain: a persistent rat infestation and a torn awning. We know the rats are attracted to a fake decorative apple inside, but their exact location within the trailer remains a mystery.
I’ve strongly advised my parents to address the rodent problem promptly before they potentially chew through the trailer’s wiring. Hopefully, this final issue can be resolved soon. With the significant water damage repaired cost-effectively, there’s a good chance this travel trailer still has several years of use and many adventures left to offer. Learning about such issues is relevant to anyone considering camper life, whether curious about are mallard travel trailers any good or another brand.
Conclusion
Severe water damage in a travel trailer, often stemming from seemingly small issues like a failed skylight seal, can lead to extensive rot and delamination, resulting in prohibitively expensive repair estimates. Our experience with the 2007 Thor Adirondack demonstrates that while a full restoration can cost $25,000 or more, a strategic and skilled “patch job” by a dealership can provide a solid, functional repair for significantly less, in our case, $7,800. This highlights the importance of early detection of signs like bubbling exterior skin and seeking professional diagnosis and repair options to prevent minor issues from escalating into catastrophic damage. While the exterior appearance may show the signs of repair, the core structural integrity affected by water damage has been successfully addressed, allowing the trailer to be used again.
