Generic Benroy Roof Panels

[Toytaco2]

I'm building my first TD using the Generic Benroy plans to build a TD 5' high x 5' wide x 9' long. Unless I have overlooked something in the plans, I have not seen any suggestions for the roof material. What thickness/type plywood would anyone suggest? It seems I have read about people using 2 layers of 1/8" or 1 layer of 1/4 in other posts. Which would work better, especially considering the curve of the roof line.

[Miriam C.]

I would definitely use 1/8 for that curve. You can also wet the ply to bend it if you use 1/4", but do it carefully so it doesn't crack.

[Toytaco2]

Would a single layer of 1/8 plywood enough or do most people use 2 layers on the roof?

[madjack]

...I thnk most people use 2 sheets of 1/8th however that is probably overkill in most situations...if you are skinning in AL, fibergalss or Filon, then 1 layer of 1/8th is definitely OK...in fact, on our latest build we are using .040 Al and applying it directly to the ribs with no substrate under it.......
madjack

[Toytaco2]

Thanks, you guys are great. I hope I can lend a similar hand of help to others as I gain experience in building a TD.

[mikeschn]

The plans are missing that tidbit of info... and someone else posted that a while back... I guess it's time for an update...

Mike....

[Miriam C.]

I used 1/8 with foam insulation snuggly under it. Glued the top to the foam. Seems strong enough but I haven't had anything try to go through it either.

[GPW]

After a limb punching 10 holes in the roof of my "commercial" camper , 1/4" or (2)1/8" on the roof might not be a bad idea... Plus some metal too ...

[Gage]

After a limb punching 10 holes in the roof of my "commercial" camper , 1/4" or (2)1/8" on the roof might not be a bad idea... Plus some metal too ...

If your going to think that way and not have insurance, then use steel sheet.

[Wolffarmer]

I put 1/8 inch brich plywood on the front and top of mine with epoxy on it. I see no problems but I don't plan on trying to stand on the top of mine. And to only push on the corners. I would have to say it is stronger than the leading edge of a light plane so I am not going to worry.

[Gage]

Well my tear is 5 wide and 10 long. The roof skin is 12 long (1 piece from forward frame to hatch). My roof is constructed of 1 piece 1/8 birch with 1x2 cross braces spaced at about 14" and laying flat. Then another piece of 1/8 birch. Oh and there is 3/4 foam board between. A person weighing approximately 205 lbs has been on top of it to fix a broken Ezup with no problem because the roof is not a flat so it is much stronger. And the addition of alum skin just adds to the strength. Anything thicker than an 1/8 is over kill unless your going to have a long flat area, then I recomment at least 1" ply for the roof.

[jdarkoregon]

Toy Taco,

I built my roof much like Gage and it is strong enough for me to walk around on, I'm 220 lbs.

the point that many are suggesting (in a round about way) is to go light. With all the glue, foam and plywood the strength of the roof is way more then you might imagine when you first start your build. Besides, if you follow their suggestions, you will even save a few bucks.

Have fun

John

[Dooner]

I built my roof with 3/4 plywood. Even the curves. But that is just the way I roll.
Older trailers and probably newer ones too, were built with roof braces or spars across with the aluminum right on that. So what ever you do above and beyond that will probably be overkill. The whole thing boils down to piece of mind. What makes you feel comfortable and makes you happy. That will be the way to go.

[GPW]

Gage, we got insurance , it's that darned "deductible"... Anybody ever use R-panel ???

[Tripmaker]

I built with a single 1/8 layer inside and out. The outside is covered with AL. With the 1.5" of insulating foam it is plenty strong.