Truck Camper Reviews

FlexArmor Four Year Review

After four years with our FlexArmor spray-on RV roof system, we report our pros and cons experience with, “The last roof your RV will ever need, guaranteed.” We also return to the FlexArmor mothership to address our cabover escape hatch and give our TV antenna the boot. First step; cut it out.

FlexArmor Four Year Review

In December of 2020, aka the last moments before Covid 19 became the only thing happening on planet Earth, we pulled into RVRoof.com south of Jacksonville, Florida. After our car accident in July of 2018, we had finally taken delivery of our rebuilt 2004 Alpenlite 1100; a process that required removing not just the roof, but the EternaBond seals. Determined to protect our considerable investment, we decided to get a FlexArmor spray-on roof system.

The process of installing a FlexArmor roof is far beyond what we had imagined. This is not a simple drive-in and spray deal. FlexArmor is a multi-faceted, multi-step, and highly proprietary process that left us both deeply impressed with the company and highly confident about the integrity of our new roof coating and seal. To get a deep understanding and appreciation for everything they do at RVRoof.com, I highly recommend reading our initial in-depth FlexArmor roof review. Long story short, our days of worrying about our roof seals or leaks are long gone.

FlexArmor Finished Camper Wide Front

FlexArmor Roof Four Years Later

I realize that some folks might have read that last sentence and concluded that FlexArmor is perfect. Well, like everything in the world, there are pros and cons. Most of these were spelled out in our initial review, but they bear repeating as they’re not only still 100 percent relevant, but have proven more prescient than we had initially thought. From the initial review, here are the pros and cons:

FlexArmor Roof Pros

FlexArmor is a 3/16-inch thick coating that covers the entire RV roof
FlexArmor coating wraps around roof edges, rear and front nose
FlexArmor has a lifetime warranty – for the life of the RV
Once applied, roof seals are eliminated with no required maintenance
Often cheaper than a completely new EPDM or TPO roof
FlexArmor eliminates EPDM or TPO windshield streaks

Four years later, I have almost nothing to subtract from the list of pros. The FlexArmor roof has proven itself to be incredibly reliable. When it rains, I don’t worry. When we brush tree limbs, I climb up the rear ladder and find nary a scratch. Sometimes we get a little mold from our camper sitting outside during our Florida winters, but it simply washes off. After years of never really knowing if our roof was truly sealed, it’s a relief to know our FlexArmor roof is so reliable. Honestly, I think it’s the most robust part of our entire truck camper. If I could FlexArmor the camper sides and underbody, I probably would.

I said almost nothing because we still get a little white residue on our windshield. It’s possible that this is from the filon on our front nose, but it happens. If we wanted to prevent this problem once and for all, we could use Jim Kaufman’s famous Mod Contest winning EZE Gutter mod. We still hear from folks who can’t believe he won the contest with that mod, but it’s a no-brainer to stop the windshield streaks.

FlexArmor Roof Cons

FlexArmor is very expensive – $170 per linear foot
Solar panels and/or roof repairs add more cost
FlexArmor can only be applied on location at a RVRoof.com installer
FlexArmor repairs can only be done by a RVRoof.com installer
Adding roof components after application is not advised
FlexArmor adds approximately half-a-pound per square foot

I can also confirm the cons have also proven accurate. The number one potential downside to a FlexArmor roof remains cost. And, like most things over the past four years, that cost has increased. As of this writing, FlexArmor is $200 per linear foot. To put that number in context, our eighteen foot hard side truck camper roof would be $3,600 today. Would I pay that amount again today if I got a new camper without a FlexArmor roof? Absolutely, yes.

FlexArmor Roof Install Close Up UV Coating

The only truly significant downside that we’ve discovered isn’t a reflection of FlexArmor, but rather the RV components installed on our roof. For example, our escape-hatch-latch (say that three times fast) failed this past summer and had a habit of opening while driving. Thanks to the team at Rugged Mountain RV, we were able to secure a new old stock escape hatch, but we could not make the swap without cutting into the FlexArmor.

FlexArmor Review Before King Jack

The other example is our King Jack television antenna that also decided to come apart mid-season. We researched the current version of this product and discovered that it too required the removal and cutting of the FlexArmor. Not wanting to jeopardize our lifetime warranty from RVRoof.com, we opted to tape our escape hatch shut (not a good idea, but gratuitous amounts of three-inch Gorilla Tape did wonders), and live without broadcast television for a few months. That proved to be a good decision on multiple fronts.

FlexArmor Review Before Gorilla Tape

Return To RVRoof.com

RVRoof.com HQ is essentially on our path between visiting our families in the northeast and returning home for the winter in southern Florida. Since our last visit in 2020, RVRoof.com has moved to Keystone Heights, Florida, about an hour and a half south and west of Jacksonville. The new location is much larger than the previous facility with multiple buildings and areas to stage RVs during the process.

We made our appointment at least a month in advance and explained what we needed done. When we arrived, there was an area designated for check-ins where we were greeted and our roof was quickly inspected. Within fifteen minutes, our truck and camper were pulled into one of their FlexArmor installation bays and analyzed for the escape hatch and antenna removal and replacement.

FlexArmor Review In The Booth

By this point, Angela and I had already decided to remove the television antenna and have the antenna installation space FlexArmored over. Believe it or not, we ended up watching the news (when compelled to do so) on YouTube on our phones. There’s even a ledge on our dinette windows that acts as a phone cradle allowing us to watch the news during dinner. Is it weird to watch television on a six-inch screen? Maybe, but it works for us.

FlexArmor Review Cutting Out Old Hatch

The RVRoof.com team tried to replace the escape hatch without doing the repair, but ultimately found there was no way to avoid cutting the FlexArmor. Once that was established, the repair began. The first step was to remove the driver’s side solar panel to give the installer space to work.

FlexArmor Review Prepped Hatch

I had foolishly thought the FlexArmor would be straightforward and fast to cut and remove. That was most certainly not the case. Even with a highly experienced installer, it was anything but a simple cut and pull. Anyone who thinks moisture or tree limbs are going to damage this material has never tried cutting or pulling it apart. Put another way, if it rained trained RVRoof.com installers with the right tools, it would still take fifteen minutes to hack into a FlexArmor roof. This stuff is serious business.

FlexArmor Review Prepped Antenna Space

I had also thought they would simply take off the King Jack antenna and spray the resulting space sealed. Wrong again. This time they created a wood insert to cover the hole and properly fill the gap. They then taped off the area and did a few other things that remain proprietary to their process.

FlexArmor Review Review FlexArmor Complete 2

Next, the team taped off the entire surrounding roof area and created an overspray backstop of cardboard. It was then that I realized this repair job was anything but quick and easy.

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FlexArmor Review Overspray Prep Plastic
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FlexArmor Review Overspray Prep Cardboard
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RV Roof Hatch Replacement

With everything prepped and protected, the FlexArmor was sprayed on, layer by layer. This part did go fairly quickly, but it was surprising to note the number of passes and angles that were needed.

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FlexArmor Review Spraying FlexArmor
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FlexArmor Review Spray FlexArmor
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RV Roof Sprayed Vent Area

FlexArmor takes a bit of time to cure before a layer of white UV coating is applied. This UV coating leaves the roof bright white, ideal for reflecting heat and it’s nearly gelcoat fiberglass in appearance.

Again the UV coating needed a little time to cure. As this happened, the installer finished the inside of our camper where the RV antenna crank had been. He also cleaned anything that fell through the escape hatch area onto the bed. These guys think of everything and truly do a fantastic job.

FlexArmor Review Review FlexArmor Completed

When everything was cured and completed, the plastic and cardboard were removed and the solar panel was reinstalled. We tested the new escape hatch and were thrilled to have that working properly again. We had been at RVRoof.com for the better part of the day, but still had enough time to drive home that day.

What’s most amazing is the repair fee. The total charge for repairs like ours is $200. When they told me this I asked if they were certain given the time and materials. I was told that most repairs like this are $200 to $300. They charge more if there are extensive wood repairs or some other unforeseen issue, but most folks leave for $200 to $300. In 2024, that’s a small miracle. Thank you, RVRoof.com. Equally important, having RVRoof.com perform the work keeps the lifetime warranty on the roof intact.

FlexArmor Four-Year Verdict

It’s difficult for me not to rave about RVRoof.com and their FlexArmor product. I realize that’s often seen as pandering to a company, but we paid for our original installation. They were so pleased with our resulting review that this repair was comped for us, but I would have happily paid for it. Seriously, if everything in this world was as good as RVRoof’s team and FlexArmor product, reviews wouldn’t be necessary.

I realize that a $200 per linear foot RV roof is out of the question for a lot of people. Or, if you change campers every few years, it might not make sense. That stated, if you have a truck camper or RV that you intend to keep until the proverbial wheels roll off, a FlexArmor installation should be considered almost mandatory. This is especially true for anyone who stores their camper outside like us. Even for folks with fancy garage-mahals, a FlexArmor roof would be a wise decision to keep your camper leak-free for as long as you own the unit. And that, my dear truck camping friends, is worth its weight in golden turnbuckles.

 

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