Help me fix my pop-up camper?

[dwils233]

Pulled the cover off my pop-up and found this crack in the plastic fairing. Due to the design profile, it does create a water intrusion when the popup is closed if raining. There's actually a few cracks to the right of the big one if you look closely

It's not resting on solid material so I don't think it's a job for caulk, but I'm looking for advice/opinions. I think a seal/patch on the top over the whole crack area from edge to edge is better than trying to fill the void.

Y'all are smart and handy though so I'm looking for your thoughts and recommended materials!

[dwils233]

Location on popup

[Platensek-po]

You could try something like this 2 part epoxy. I used it to
Fix a couple
Of kayaks and it’s held up well.

https://www.amazon.com/655-8-Pre-Thickened-Part-Epoxy-Adhesive/dp/B00LWKFZJ8/ref=asc_df_B00LWKFZJ8/?tag=hyprod-20&linkCode=df0&hvadid=693270349644&hvpos=&hvnetw=g&hvrand=4002036735243988010&hvpone=&hvptwo=&hvqmt=&hvdev=m&hvdvcmdl=&hvlocint=&hvlocphy=9033553&hvtargid=pla-574123118372&psc=1&mcid=c0880f8ec6d13b529345d9c87c46ec54&gad_source=1

[MADMAX]

Love this stuff

[CP]

I’d try welding it.  Imbed a couple of staples to strengthen it and keep it from re-cracking.  Preferably, stainless staples. 

If you search YouTube for “plastic welding” you’ll find several how-to videos.

[baker5150]

I'd simply use caulking.  Sikaflex or Vulkem are my go-to.
You may also get away with a butyl tape that has a UV backing.

There is a reason it cracked and separated, so unless I knew why and could fix the root cause, I would want whatever repair I do to be able to move and flex while also staying sealed.

[Sneaky Squirrel]

I'd simply use caulking.  Sikaflex or Vulkem are my go-to.
You may also get away with a butyl tape that has a UV backing.

There is a reason it cracked and separated, so unless I knew why and could fix the root cause, I would want whatever repair I do to be able to move and flex while also staying sealed.

I would agree with this. On the first picture, it looks like there is a nail or staple coming thru the wood. Wondering if when they were installing the plastic and snapping/attaching it, it caused it to crack as it is protruding out. If that is the case, seems like any of the options above would work but i would try to cover at least 6" coverage just in case if it breaks more.

[dwils233]

There is a reason it cracked and separated, so unless I knew why and could fix the root cause, I would want whatever repair I do to be able to move and flex while also staying sealed.

Bingo, that's why I wasn't sure best approach. If the plastic was hardened and then cracked on expansion/shrinkage, I want my fix to account for that in the future. Silicone has some flex, but you think the poly base would be better? I can't really fill the cavity, I need to essentially do a thin fill and focus on edge to edge adhesion across the gaps

[hunter399]

They have flex seal tape.
We used it on a swimming pool last year. While it had water in the pool leaking. Put that tape on the outside and it stopped leaking.

Anyway it shocked me how well it worked.

Look up flex seal tape on Amazon

[rainshadow1]

It is a job for caulk, just slightly more caulk than usual! I'd use pure silicone.

[Platensek-po]

I disagree. Caulking sucks. Especially for outdoor purposes. If you use caulking it’ll dry out and degrade in the sun and be leaking again sooner rather than later.

[Dan-o]

Flex Seal. 

You can use the extra to build a boat. 

Seriously, I used Flex Seal on a leaky sunroof in my truck. Hasn't leaked in 10 years since.

[elkaholic123]

There is rolls of tacky tape they use for sealing around skylights. I got some that was 4 inches wide and you peel the surface wax paper off and it sticks and doesn’t let go, you can purchase it at any rv parts store!

[Wood2Sawdust]

Not silicone , it does not last long . Also if you have old tubes of silicone it sometimes will not set up. Sikaflex has worked for me on other parts of trailers

[Wood2Sawdust]

I have also used the flex seal tape with good results.  Cracked a skylight going to elk camp, taped it three years ago still good