To help address SportCam leaks the whole rooftop air conditioner was removed. Once gone it was easier to "read" the roof distortion. It's true. A picture can tell a story.
Turns out the roof was strong enough for the AC's weight. The problem was how it was installed. The left and right shell halves met in the middle with slight uphill slope from each side. The slight "ridge" was capped with a trim strip to hide the seam. Which further accentuated the roof ridge. Note: the AC unit was flat, and steel; thus rigid. When sandwich bolted above and below the roof, the flexible and unflat fiberglass got deformed. The roof flattening effect was compounded by the raised ridge trim. Once driven down to match the sides a valley was formed that trapped rain water. Poor design, sigh.
So how to fix it. After 23 years that's the only shape this roof remembers. My goal was to correct the sunken part around where the AC sits. Not necessarily to match the original sloped sides and pronounced ridge. Instead, to form a curved arch to the roof around the AC area. Some reference measurements informed a target geometry. A pair of ribs were trimmed from 2x4s. A flexible fiberglass rod constrained by dog screws was used to establish the path of curvature.
The sculpted ribs were placed fore and aft of the access hole through the roof. The ribs were jacked up and blocked in place to flex the roof up to target height and shape. Once dry fitted the ribs were epoxy glued and screwed to the ceiling. A little over spring was added to allow for settling.
Futher mods will come with reinstallation of the AC unit later this summer. Meanwhile, the corrected roof is now crowned and therefore better poised for April showers. A list of remaining leaks need attention next.
