Raise the ROOF!

This is how we lost our sanity…. (or part of it)

Restoring a 1998 Coleman Pop-Up Camper, like Neverland, can be a rewarding but challenging process. One of the most important aspects of the restoration was addressing the ABS (Acrylonitrile Butadiene Styrene) plastic layer that had been damaged over the years. The ABS coating had become cracked and delaminated (major separation of the ABS from the fiberglass), and so we had to completed remove the top layer of ABS and replace it. We ended up peeling it off (ALMOST IN ONE WHOLE PIECE!), removing the liquid concrete that was used to reinforce it, and patching the holes with bondo. There were some areas that needed covering where the fiberglass peeled from the foam, so we used fiberglass cloth and resin. Finally, we applied a bedliner to give it a durable, textured finish that will stand up to the elements. Here’s a detailed guide on how we tackled this restoration project, step by step.

Materials You’ll Need:

Utility knife or scraper
Heat gun or hair dryer (optional, for easier removal if yours isn’t delaminated like ours)
Bondo filler
Fiberglass cloth
Fiberglass resin
Paintbrush or roller
Sanding block or sander
Bedliner spray
Rags or paper towels
Respirator mask (recommended for safety)
Gloves (recommended for saftey)

Step 1: Preparing the Camper Surface

The first step in this restoration process is to prepare the surface of the camper by removing the damaged ABS layer. This step is crucial to ensure the bond between the materials you’re using holds up well.

Clean the Surface: Start by cleaning the area of any dirt, debris, or grease. Use soap and water to wash the surface, followed by a rag to wipe it dry. This helps prevent debris from getting on the fiberglass layer.
Heat the ABS (Optional): If you’re dealing with stubborn ABS, you can use a heat gun or a hair dryer to soften it a bit. This will make it easier to peel off in larger sections. If using heat, be sure to use a lower setting to avoid warping the underlying material.
Peel Away the ABS Layer: Start peeling the ABS plastic layer from the camper. Use your scraper or utility knife to gently lift the plastic. Be careful not to damage the material underneath, especially the fiberglass or wood structure. The ABS layer should come off in chunks or strips, revealing the underlying surface.
Remove the Seal: Once the ABS is off, the black bulb seal may start to fall off. Go ahead and remove this. If it is still in good condition, save it for later, if not, you may need to replace it.

Step 2: Repairing Damaged Areas with Bondo

Once the ABS is removed, you’ll likely notice some cracks, holes, or other damage on the surface. This is where Bondo comes in—this filler is great for smoothing out imperfections and creating a solid, even base.

Mix the Bondo: Follow the manufacturer’s instructions to mix the Bondo filler with the hardener. Make sure to mix it well until it has a uniform consistency.
Apply the Bondo: Using a putty knife, apply the Bondo to any damaged areas on the camper. Make sure to fill any cracks, holes, or voids, and smooth the filler over the surface to ensure an even finish. Be generous with the application but remove any excess filler for a cleaner finish. Hint: Work in small amount to make sure you have time to smooth the Bondo to reduce your sanding efforts later, as this dries extremely quickly.
Allow the Bondo to Dry: Let the Bondo cure for the recommended amount of time (usually about 30-45 minutes, depending on the temperature). It will harden and become firm to the touch.
Sand Smooth: Once dry, get an 80 grit sanding block or sand paper, and sand down any of the sharp edges. Note: We did not sand completely smooth. The bedliner spray later WILL show any imperfections, but that will not lower the integrity. We decided that once it is popped up, no one would see the roof so it mattered less to us.

Now, please be smarter than us, and remember to Bondo the areas with the latches to smooth the sharp edges of the ABS before moving forward onto the fiberglass!

Step 3: Reinforcing with Fiberglass Cloth and Resin

Fiberglass reinforcement is an important step to add strength to the camper’s surface. This is especially useful if there are larger cracks or areas that need extra durability.

Size the Fiberglass Cloth and Cut/Tear: Cut the fiberglass cloth to fit over the areas you’ve patched with Bondo. Make sure the cloth is slightly larger than the area you need to cover for a better bond. Hint: Some fiberglass cloths need to be torn and not cut. We used a chopped strand mat that needed tearing rather than cutting to protect the integrity of the strands.
Mix the Fiberglass Resin: Follow the instructions on the resin kit to mix the resin with the hardener. Make sure to do this in a well-ventilated area and wear a respirator mask for safety. Note: We used KN95 masks and additional fabric masks on top to keep a good seal. It’s not the safest, but it is what we had.
Apply the Resin: Using a brush, apply a thin layer of resin over the Bondo patches. Then, carefully lay the fiberglass cloth over the wet resin. Once the cloth is in place, use the brush to apply another layer of resin on top of the cloth. The resin will soak into the cloth and bond it to the surface, providing extra strength. Don’t skimp on the resin, it provides the strength you need, so apply liberally and get more than you think you will need.
Allow to Cure: Let the fiberglass resin cure for at least 2-4 hours, or as recommended on the resin instructions. It will harden, creating a solid, reinforced surface. We are in a colder climate so we checked it after 24 hours and it was mostly hardened. We waited an additional 24 hours before sanding.

Step 4: Sanding and Smoothing

Once the fiberglass has fully cured, it’s time to smooth the surface so that it’s even and ready for the next step.

Sand the Surface: Start with a medium-grit sandpaper (around 80-100 grit) to remove any rough patches or excess resin. Then, gradually work your way up to finer sandpaper (220 grit or higher) to get a smooth, even surface.
Clean the Surface: After sanding, clean the surface with a rag and some water to remove any dust or debris. This is crucial for getting a clean finish when applying the bedliner. I recommend doing a double clean. Clean once, then refresh the water and clean again so that any smaller particles are lifted. This is one step that it really matters as once you apply the bedliner, you can’t go back.

Step 5: Applying the Bedliner

To give Neverland a durable, textured finish that will protect it from the elements, we used bedliner spray. Bedliner is designed to resist abrasions, UV damage, and water, making it perfect for a camper exterior.

Mask Off Surrounding Areas: Before applying the bedliner, make sure to mask off any areas that you don’t want to be sprayed, such as windows or trim. We used painters tape to tape plastic sheeting to the inside of the roof/ceiling. This gave us access to the edge of the roof to reinforce with the bedliner.
Apply the Bedliner: Shake the bedliner can thoroughly and spray in even, overlapping strokes. Start with a light first coat and allow it to dry according to the manufacturer’s instructions. Once the first layer is dry, apply a second coat to ensure full coverage. Note: For Speedokote, which we used, our 12ft camper needed 6 quarts at minimum, 8 for very thorough coverage. The instructions on Speedokote was for one solid layer at 60-80 PSI, let it set for 2 min, and then do a light coverage at 80 PSI.

Allow to Dry: After applying the final coat of bedliner, allow it to dry completely (usually 24 hours). This will ensure the surface is fully protected and ready for any future camping adventures.

Step 6: Final Touches

After the bedliner is fully dry, take a step back and admire your work! The surface should be smooth, durable, and protected from the elements. You can also do a final inspection and touch up any areas that may need a little extra attention.

We decided to take some Flex Seal on any of the areas that had small missed spots and make sure that we could not see the fiberglass underneath.

This is also the time to reattach the bulb seal. We used gasket glue to secure it to the roof as once the ABS is removed, the thickness of the roof is quite a bit thinner and might need some extra strength to hold the seal.

Conclusion

Removing the ABS layer and repairing it with Bondo, fiberglass cloth, and resin was an intensive but rewarding process. By reinforcing the surface with fiberglass and applying a bedliner, Neverland now has a durable, weather-resistant finish that will last for years of camping adventures. With this step-by-step guide, you should be able to tackle similar repairs on your own camper or vehicle and give it a brand new lease on life!

Until next time, happy camping!🌲

— The Team at Camping in Neverland

Katie and Cam

Owner of Neverland

Camping in Neverland