Passport 238ML Front Cap Delam

[Fisherman J]

Hello Everyone,

First post here.

We recently bought a used 2013 Passport 238ML at a good price that was sold as/is but safe and functioning. We were shown some minor normal repairs like latches,lights etc and that the front cap had started to delaminate.

When we looked at the delamination the first time it appeared fully sealed with no evidence of water intrusion.

At second look we noticed some seals deteriorating throughout the unit (perfectly normal) and thoroughly searched for water intrusion. No signs of water in the unit with the exception of a tiny bit around the doors of the front pass through (normal for it's age and door)

After getting it home I noticed the front cap that was sealed now had about a 25mm opened seal and once the sun hit the front cap you could really see how wavy it was.

My concern is there was water intrusion and the entire front wall has delaminated but I have see that these models have a "floating wall". Nothing seems soft under it and no mould smell/symptoms.

My question is how much of this is delamination vs the floating wall/normal wear and tear?

If the entire front cap is delaminated is it worth fixing or do I just seal it and ride it until the wheels fall off?

Any help is greatly appreciated. Thanks.

 

[NH_Bulldog]

It isn't delamination like you might see on the sidewalls. The front and rear are simply sheets of Filon (fiberglass reinforced plastic) that are attached at the top and draped down and secured at the bottom and edges (as you noted, a floating wall). You can lightly press on the surface in the middle and it will easily flex because all that is behind it is a rough frame and fiberglass batt insulation. The assembly is nothing like the bonded "sandwich" sidewalls. On our 2019 Passport, I could look in the rearview mirror and watch the surface flex and undulate as we drove down the highway.

You might be able to pull out that white plastic strip (screw cap) and then loosen the trim and see if you can flatten it out (or replace the face entirely if you were ambitious enough). The material comes rolled up like a carpet and can be found at many RV dealers or online.

Personally, I would just loosen the trim and make sure it is well-sealed across the rooftop transition and down the sides and leave it alone otherwise.

 

[Fisherman J]

It isn't delamination like you might see on the sidewalls. The front and rear are simply sheets of Filon (fiberglass reinforced plastic) that are attached at the top and draped down and secured at the bottom and edges (as you noted, a floating wall). You can lightly press on the surface in the middle and it will easily flex because all that is behind it is a rough frame and fiberglass batt insulation. The assembly is nothing like the bonded "sandwich" sidewalls. On our 2019 Passport, I could look in the rearview mirror and watch the surface flex and undulate as we drove down the highway.

You might be able to pull out that white plastic strip (screw cap) and then loosen the trim and see if you can flatten it out (or replace the face entirely if you were ambitious enough). The material comes rolled up like a carpet and can be found at many RV dealers or online.

Personally, I would just loosen the trim and make sure it is well-sealed across the rooftop transition and down the sides and leave it alone otherwise.

That's what I thought as well. There has been definitely a little water intrusion along the seams but everything is dry (confirmed with moisture meter) There seems to be 2 types of bubbles but it all feels solid underneath. Next nice run of good weather I'm going to open it up and talk a look inside. My wife thinks we should just fill it with spray foam and seal it up but I know how nasty that stuff is to remove if you need to.

 

[Wantoride]

That's what I thought as well. There has been definitely a little water intrusion along the seams but everything is dry (confirmed with moisture meter) There seems to be 2 types of bubbles but it all feels solid underneath. Next nice run of good weather I'm going to open it up and talk a look inside. My wife thinks we should just fill it with spray foam and seal it up but I know how nasty that stuff is to remove if you need to.

It’s definitely water intrusion. My 2014 passport sprang a tiny leak in the roof membrane where it joins the front cap 3 years after we purchased it new. You probably have a soft floor in the trailer somewhere. I have since sealed the edges where it’s buckled and don’t seem to have any water intrusion anymore. I had to cut the black plastic sheet on the underside to release the water and moisture. These particular keystone trailers were really poorly made.