Let’s talk about one of the most dreaded aspects of RV ownership – roof maintenance. It’s literally out of sight, out of mind until you have a problem. And when that problem is water pouring through your light fixture during a downpour (yes, that actually happened to us), it quickly becomes a top priority!
The Reality of RV Roof Maintenance
Most RV owners fall into one of two categories:
- Those who diligently climb up and reseal their roofs every year
- Those who don’t think about it until water starts coming in
We found ourselves in the second category, and it was a harsh wake-up call. During an investigation of our solar system, Barry peeled back some sealant and thought he had properly resealed it. But the first major downpour we experienced resulted in water streaming into our RV through a light fixture. Not exactly the indoor water feature we were looking for!
This incident made us realize how vulnerable standard RV roofs really are. Even with the best intentions and maintenance, traditional roofing materials like TPO or EPDM rubber are susceptible to:
- Punctures from tree branches
- UV damage and deterioration
- Seams that can separate over time
- Sealants that inevitably fail
Why We Chose Flex Armor for Our RV
After our leaking disaster, we knew we needed a better solution. That’s when we connected with Flex Armor, a company that’s been perfecting RV roofing systems for over 20 years (with 33+ years in the sealant business).
What made FlexArmor stand out to us:
No More Annual Maintenance
The biggest selling point for us was eliminating the need for annual recaulking and inspections. As full-timers, the last thing we want to worry about is climbing on our roof every year or finding someone to do it for us.
Lifetime No-Leak Warranty
Flex Armor offers a lifetime warranty against leaks that’s even transferable to the next owner. For us, this peace of mind is invaluable.
Superior Protection
The sprayed-on polyurea coating is approximately 1/16 inch thick – substantially more robust than standard rubber membranes. It’s tough enough to resist punctures and damage that would easily penetrate traditional roofing materials.
Environmental Benefits
We’ve already noticed that our RV stays about 10 degrees cooler with the new roof. The white surface reflects heat, and the material provides additional insulation.
Sound Reduction
An unexpected benefit has been the significant noise reduction. When parked under trees dropping acorns, we used to hear every impact. Now, it’s remarkably quieter inside our RV.
The Installation Process
One thing that sets FlexArmor apart is their controlled installation environment. Unlike some competitors who offer mobile services, Flex Armor requires you to bring your RV to one of their 40+ facilities across the country.
Here’s what our installation process looked like:
Day 1: Preparation
We arrived at the facility and set up at their onsite hookups. The team began by:
- Removing all items from the roof, including our six solar panels, air conditioners, and other components
- Carefully marking and documenting all solar panel connections and mounting positions
- Stripping off all the old caulking
- Thoroughly cleaning and prepping the surface
- Making any necessary wood repairs
Day 2: Application
The second day involved:
- Final surface preparation
- Applying primer
- Spraying the polyurea coating
- Applying the UV protective topcoat
The spraying process is fascinating to watch! The material dries in about 6 seconds, allowing the technician to carefully control the application. Throughout the process, quality checks ensure perfect coverage with no weak spots.
Day 3: Reassembly
On the final day, the team:
- Expertly reinstalled our six solar panels in their exact original positions
- Reconnected all solar wiring and mounting systems perfectly
- Reinstalled air conditioners and all other roof components
- Performed final inspections to ensure everything was working properly
- Returned our RV to us, ready to hit the road
We were particularly impressed with how they handled our solar panel system. Having six panels removed and reinstalled could have been a nightmare, but they did it without a hitch. Everything was working perfectly when we got back on the road – a testament to their attention to detail and expertise with all types of RV setups.
Pros and Cons of the Flex Armor Roof
Let’s be transparent about the complete picture:
The Pros
- Lifetime warranty that’s transferable to future owners
- No annual maintenance required
- Superior protection against leaks and punctures
- Temperature reduction inside the RV
- Noise reduction from rain and debris
- Peace of mind for full-timers and weekend warriors alike
The Cons
- Cost: At approximately $200 per linear foot, a 40ft roof costs around $8,000
- Facility visit required: You’ll need to travel to one of their locations
- Time commitment: 2-3 days for the installation
- Added weight: Approximately 175 lbs for a 40ft RV (though this is offset by removing old materials)
Is a Flex Armor Roof Worth It?
For us, this comes down to a simple question: What’s peace of mind worth to you?
If you’re a full-timer like us, water damage can be catastrophic. It can force you off the road, lead to expensive repairs, and potentially cause mold and health issues. Even for weekend warriors, discovering water damage after your RV has been in storage can ruin your vacation plans and significantly decrease your RV’s value.
While the upfront cost is substantial, it’s less than half the price of replacing a TPO roof ($16,000+ for a 40ft RV). More importantly, it eliminates one of the biggest ongoing maintenance headaches of RV ownership.
Options for Getting a Flex Armor Roof
The process is surprisingly convenient. You can:
- Drive your RV to one of their 40+ locations
- Have your RV transported to a facility
- Drop off your RV while you take a vacation elsewhere
Most installations take only 2-3 days, and the company is expanding their locations to make the service even more accessible.
Our Final Verdict
After experiencing our new FlexArmor roof, we can confidently say this is one of the best investments we’ve made in our RV lifestyle. The combination of eliminated maintenance, superior protection, and lifetime warranty makes this a clear winner for us.
Is it the cheapest solution? Definitely not. But as with most things in life, you get what you pay for. For us, never having to worry about roof leaks or annual maintenance again is worth every penny.
Have you had experience with RV roof issues or alternative roofing solutions? We’d love to hear about it in the comments!
Find FlexArmor at RVroof.com
Disclaimer: While we partnered with Flex Armor for this video, our opinions are entirely our own based on our real-world experience with the product.
