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Old 04-03-2022, 11:34 AM   #1
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Honeycomb ceiling removal

C5500 shuttle fiberglass roof sags, can I remove the inner layer and honeycomb and reinforce

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Old 04-03-2022, 12:57 PM   #2
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Originally Posted by rollin donut View Post
C5500 shuttle fiberglass roof sags, can I remove the inner layer and honeycomb and reinforce
Blu88 had a similar problem with his Chevy 5500 shuttle. His solution looks sturdy. (link below)
https://www.skoolie.net/forums/f27/s...aps-37272.html
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Old 04-03-2022, 06:52 PM   #3
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I had seen his post, I thought sturdy as well but wondered if anyone had removed the inner layer
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Old 04-04-2022, 10:58 AM   #4
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Not sure if I've seen anyone systematically address the sag problem (other than Blu88 ). It must be a common issue with older shuttles. Occasionally in other forums I've seen posts that someone removed the inner layer and the honeycomb, but no pictures.

The sandwich of 1/8" fiberglass and cardboard honeycomb is structural, as you probably know. If it's sagging that means the integrity of that 'sandwich' is compromised, though honestly I'm not sure whether that matters other than visual appeal or water pooling.

Shuttles have high enough ceilings that you don't necessarily need to remove the inner layer and cardboard to fix the sag. That will be a tough, dirty, messy job; and besides, the honeycomb, or whatever is left of it, provides continuous support for the fiberglass--without it I'm not sure you could walk on the roof afterwards.

If I had to address it I'd probably see if I could get away with building plywood trusses, maybe 2-1/2" deep, that conform to the original slope and curve of the ceiling and support it where it's sagging.
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