The biggest eye sore on the airstream has been the oversized, after-market swamp cooler. I wanted it taken off the second it hit our driveway, but removing it required the skills of a talented metal guy. That’s where our friend Hot Rod Ron comes in. Ron came over today to help Matt seal the roof up, after Matt took off the evap cooler. After the existing metal was exposed under the evap cooler, Ron used a cut-off wheel to cut the metal straight, both on the roof and inside the ceiling. They then went to go pick up 2 sheets of aluminum, a tube of silicone and a rivet gun to patch the roof. Matt cut the aluminum sheets down to size and Ron walked Matt through the patch job. We have to get some insulation before we patch up the inside, but that will happen in the next day or so. Thanks Ron for all the help today. We owe you big time!
Project # 9: Remove Evaporative Cooler From The Roof
August 19, 2011 by airstreamy
airstreamy 
Do *NOT* use silicone to seal between aluminum sheets (the panels of the skin, the patch you put for the space where the swamp cooler was, etc.) Over time the acetic acid in the silicone leeches out and etches the aluminum, eventually it’ll eat holes in a panel. Sikaflex or Vulkem (now Trempro 636) are what Airstream recommend to seal panel seams and penetrations.
Where that awful swamp cooler was might have been one of the original roof vents, unless you have one of those just forward of the hole for the swamp cooler. Fantastic Fan is a good power vent if you have a hole to fill, they have nice features like automatic closing if it rains, and thermostatic operation.
Thanks for the tips. We thought about adding another vent, but there are 2 up there already. The hole for the evap trunk was pretty big, so we felt compelled to cover it with new skin. I’m not sure what options we have for switching the silicone out, but I think you have some good points. We are totally learning as we go!
I have been reading up on the fantastic fans. I think we may need to replace our manual vents soon, as one of them has a crack and will probably cause a leak.