Front end filon repair

[Dave B]

We have a 2009 Sprinter trailer that's suffering from bubbling in the filon front end up near the roof. (Dont get me started about the ridiculously poor construction and design.) Repair shops want $1500 to $2000 and up to repair it and all they'll do is replace it with the same filon skin backed up by the cardboard style material that failed in the first place.

I'm strongly considering pulling the trailer in to the shop this winter and doing the repair myself. I can either use filon backed with something of my own design, or I also have access to painted aluminum which at the moment seems the best choice. My only major reason to hesitate is that I'm not familiar with the "right" way to attach and reseal all the seams.

I've looked on-line and although there's a ton of videos and other info about filon repair, I haven't found one that shows how to properly handle seams. I'm sure it has to be there but I just haven't found it.

Does anyone know of a good source of information? Ideally it would be a step by step demonstration with information on the right products to use. (I know, I don't want much[emoji38])


Sent from my iPhone using Tapatalk

[Frank G]

I think the main reason they use Filon on the front is that it can be applied in one piece, without any visible screws. The painted aluminum is normally 4'X8' with some colors available in 5'x10' .030 and .040 thickness. If you can deal with a center seam you may want to consider 2 mil ACM, (aluminum composet material) aluminum on both sided with a plastic core. It has been around for a few years now and is the go to material in the outdoor signage market. It will conform to a gentle radius. Trade name: dibond

[Dave B]

Originally Posted by Frank G

I think the main reason they use Filon on the front is that it can be applied in one piece, without any visible screws. The painted aluminum is normally 4'X8' with some colors available in 5'x10' .030 and .040 thickness. If you can deal with a center seam you may want to consider 2 mil ACM, (aluminum composet material) aluminum on both sided with a plastic core. It has been around for a few years now and is the go to material in the outdoor signage market. It will conform to a gentle radius. Trade name: dibond

Thank you. I'll check it out.


Sent from my iPhone using Tapatalk

[Dave B]

I just did some looking at dibond, and it certainly looks like a good idea. None of the sites I saw talked about bending it, however. I'm not sure it would take the radius at the top edge and it's too expensive to buy and test. I wonder if anyone has actually tried it?


Sent from my iPhone using Tapatalk

[Frank G]

Below is a link to fabricating dibond.

https://graphicdisplayusa.com/downlo...May%202011.pdf

I believe "dibond" was the original. There are now many copy cats from China and else ware. Any self respecting sign shop should have samples and can order for you. White should be stock. White also cones in a one sided version with a thin aluminum backer at a reduced price. I used to get this stuff for about $48.00/4x8 sheet.

Now, if you look at the fabrication guide you can rout or saw cut grooves on the back side allowing you to conform to a tight radius.