DIY: Replaced the delaminated front Filon on my trailer!

[IQRaceworks]

I picked up a 2011 Zinger 19RDS last year for a steal.....mostly because it had a few bubbles in the sheet of filon material that is wrapped over the front of the trailer....it was starting to delaminate. Even though I had gone through it and resealed everything, it seemed like every month that went buy, the bubbles, wrinkles and warping on the front got worse. It finally got bad enough where I decided to do something.



I took the molding off on both sides, the bottom side where it joined the chip/rock guard, and top where it joined the metal roof. After that was all off and cleaned up, the front pretty much just came right off. It was actually in better shape than I thought....I think most of the moisture must have got in around a marking light at one time. (Every time I mess with this thing I'm amazed at how cheap it's built!)





So once I had the sheet of filon off, I got two powder coated 4x8 sheets of .020 aluminum sheets from a local metal supply house. I overlapped them 10", and joined them with some 3M VHB structural double sided tape, and 3M 5200 marine adhesive....and let it dry a few days.



I then started the tedious process of adjusting, fitting, and adjusting some more, until I got the aluminum sheet centered up and aligned just right. Next I started screwing down all of the trim, and sealing everything back up.



The finishing touch was to put a piece of .040" aluminum diamond plate on the front to replace the ugly white metal chip guard what was on it.

All finished....what do you think? When it was all said and done, it cost me around $200. Now I just need to put some graphics back on the front.

[OhioMark]

Nice work!

You might have a side business waiting for you. There are alot of trailers out there out of warranty with delamination issues. Looks great.

[Lloyd]

Looks like a new one now. Nice job!

[Wingchop]

Nice job. I did the same project on my 2007 Sunset Trail 29rl. The project is doable but I found you just need to take your time and have an extra pair of hands at the right time. While I had the front off I replaced the clearance lights and front lamp with leds and put in a couple of reading lights above the master bed (real easy with the front off).

The only thing I did different was to have the metal shop put 'S' bends on one end of each 4X8 sheet to keep it water tight.

I also was disappointed in the workmanship of the trailer, mostly little things like the fit of the insulation and cleanliness, but to do it right would cost the company almost no money but would really improve the trailer.

I think my leak also came from the clearance lights. For 50 cents I put the wires through grommets and a little caulk that should water proof the front end for my lifetime. Something that could have been done when the trailer was built (50 cents) and would have saved me hundreds of dollars.

I'm probably average on the handyman scale and found this project well worth the effort. I went overboard on caulking and sealing but figured the small increase in cost will be minimal for the life of the trailer.

I used Dicor corner seal tape and the eternabond bond tape where the sheet metal meets the roof, this worked really smooth.

I googled 'Sunset Trail decals' on Ebay and found some real reasonable decals, under $30.

Like your project our trailer looks as good as new.

[Dayle1]

Looks better than new and should hold up better as well. Great job.

[sjk1998]

Very nice job. Looks good.

[mark5w]

Very professional looking. Great job

[OhioMark]

Now all you need is a new label...

[cubfan]

A truly nice job. You have a real knack for this. I would agree with OhioMark and do yourself proud.

[GBZY]

Very Nice.

[heatherbella]

Well done!

[Aceallenk]

I agree, it looks like a brand new one. Personally looks real clean without the decol. Something I would consider not replacing, but thats just me.

[sleepyT]

I agree with Aceallenk and when people ask what happened to your decal you can explain what a crappy job CR did and you had to replace...

[Biggles607]

Spectacular job......

I'm in total agreement, put your own logo up there. The front looks better than factory.

I do love that polished diamond plate.