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5 RV Flex Armor Problems: Detailed Solutions Guide

Are you facing the frustrating RV Flex armor problems? Don’t worry! You are not alone. I have also been through this issue and luckily I found some of the most reliable solutions. Flex armor problems can arise due to bad rubber roofs, AC mounting, and shower cubicles.

Read on as I will share the 5 best working solutions along with people’s experience with the Flex armor. So without any delays, let’s dive into the details!

How To Fix RV Flex Armor Problems: 5 Solutions Listed!

A Detailed Overview of Flex Armor

Flex Armor has gained attention as a spray-on roofing material designed to revolutionize RV roof protection. It is a product that has quietly existed since 2005, serving the purpose of protecting the roofs of your recreational vehicle. These Flex armors are crafted from high-grade pure polyurea for securing your RVs in extreme conditions.

A Detailed Overview of Flex Armor
Credit: www.youtube.com @Bill Wano

Here are a couple of important highlights you should know:

  • Flex Armor extends its protective capabilities beyond standard roof coverage, including shower skylight.
  • Upon application, RV owners can expect a significant 3/16-inch protective coating that spans every inch of their roof.

All these unique features make this product a promising option for those seeking lasting roof protection for their recreational vehicles.

With Flex Armor, your RV gains more than just a roof; it gains the shield against the unexpected. No more worries about tree incidents or costly repairs.Roger Blake, A mechanical engineer and RV expert

5 Most Common RV Flex Armor Problems and Their Solutions

As I mentioned earlier, I also faced this issue when applying Flex armor to the vehicle’s roof. In this section, I’ll discuss common issues associated with RV armor and share solutions for these challenges. Let’s dive further:

Problem 01: Faulty Rubber Roof Structure

RV owners can come across defective batches of rubber roofs produced.

  • This manufacturing glitch will primarily affect the upper white or tan side of RV rubber roofs.
  • As a result, the rubber can remain sticky, soft, or powdery to cause adverse effects on the appearance of the RV roof.
Problem 01: Faulty Rubber Roof Structure
Credit: www.youtube.com @TSquad RVing

Note: I remember I failed to notice this problem earlier because of how slowly this faulty rubber roof caused damage to RV ceilings.

You may also notice the front of the rooftop ballooned up due to entrapment of the air. It is particularly prominent around the AC and 5th wheel area of your RV because of the moist conditions. Additionally, you may also experience a tear in the roof membrane due to the low-hanging branches of trees. All these RV roof issues have a particular solution, which I will discuss below.


Addressing a faulty rubber roof begins with thorough preparation such as:

  • Clean the RV Flex armor roof surface.
  • Removing oxidation and dirt with a residue-free cleaner.
  • Cut the EPDM patch material, ensuring it extends at least 2 inches beyond the damaged area.
  • Get the damaged RV Flex armor area ready by putting EPDM rubber primer on it.

Then, do the following steps based on the type of patch you’re using:

For a Pressure-Sensitive Patch

Here are a couple of quick fixes for the pressure patch:

  • Remove backing, apply the patch, and press it down firmly.
  • Roll the patch in multiple directions to eliminate air bubbles.
For a Glue-Down Patch

Apply single-ply EPDM adhesive to both membrane roofs. Then, follow the guidelines listed below:

  • Allow it to dry until not tacky, then press the patch firmly.
  • Roll the patch to remove air bubbles and eliminate roof damage.

Problem 02: Air Conditioner Not Mounted Properly

You may see that the gasket between the rubber roof and the AC unit may be damaged or not provide a proper seal. This issue can lead to:

Problem 02: Air Conditioner Not Mounted Properly
Credit: www.youtube.com @RV 101
  • Water leakage due to openings and spaces between AC and Flex armor.
  • It is also possible that the bolts securing the AC unit may be loose or misaligned, affecting the sealing of the unit.

I have also observed condensation formation around my 14-inch AC opening. If not properly managed, it can lead to water accumulation and potential issues with the AC unit and the surrounding Flexarmor roof material.


In my opinion, applying a sealant proves beneficial in preventing water infiltration. In case of deterioration, opt for the following measures:

  • The gasket needs to be replaced to maintain the seal and protect against leaks.
  • If you want to resolve this AC-related issue, remove the bolts securing the air conditioner from inside the coach.
  • Afterward, proceed to lift the unit off the gasket on the roof.
Problem 02: Air Conditioner Not Mounted Properly

During the installation of a protective layer on your roof, you should disassemble the air conditioners before applying a spray up to the opening. Finally, you can replace the existing gasket with a new one.

Problem 03: The Shower Cubicle Skylight Problem

RV skylights often have a bunch of problems at the same time, which can also extend to damaging RV roofs. The outside plastic used for RV skylights can get:

  • Foggy;
  • Turn Yellow;
  • Become brittle after being exposed to the sunny weather of Green Cove Springs.

Sometimes, it can even cause the roof material to break and cause leaks if not dealt with timely. The inside plastic part of the skylight can also cause trouble to RV Flex armor.

Problem 03: The Shower Cubicle Skylight Problem
Credit: www.youtube.com @Chasing the Joneses – Full-Time RV Life

In addition, water droplets and dirt can build up between the inner and outer parts of the skylight. If the glue holding the see-through part to the outer ring gets weak, the inside roof coating might even come off.


For effective cleaning inside the RV skylight cover:

  • Use a moist cloth before reinstalling the liner.
  • Once it’s in place, those areas become hard to reach for cleaning.
  • Be cautious when reattaching the RV skylight liner; use screws to secure it in the opening.
  • If you need to replace the shower skylight, you can make a small cut in the flexible roof.
  • Alternatively, you have the option to remove the entire old skylight and replace it with a new one.

Problem 04: Peeling, Cracking, and Color Fading of RV Roof Paint

When you observe peeling on your roof, it could be a result of applying the protective product incorrectly. Flaws in RV construction, including fading and cracking issues, can lead to unexpected expenses. Plus, undermining the effectiveness of the protective coating, potentially causes further roofing problems.

Problem 04: Peeling, Cracking, and Color Fading of RV Roof Paint

First and foremost, you have to follow the manufacturer’s guidelines for applying the protective product. In addition to that, I will insist you choose a high-quality RV protective coating that is suitable for your roof’s type. Furthermore, ensure thorough cleaning and proper preparation of the RV roof before applying the protective product.

  • Remove any existing paint or coatings from the roof.
  • While applying a protective coating, pay attention to factors such as temperature, humidity, and drying times.
  • Ensure that the RV protective coating you choose is compatible with the RV construction material and offers UV resistance to mitigate color fading and enhance long-term effectiveness.

Problem 05: Expensive Rates of RV Flex Armor

Many RV owners, including myself, find the cost per linear foot for applying RV roof protection products to be on the higher side. In my research, I found that bringing in an authorized dealer to carry out this service would be approximately the same cost as a standard roof replacement.

Problem 05: Expensive Rates of RV Flex Armor

So, this fact proves that the expenses of these protective layers are comparable to completely replacing the roof of the RV.


The most effective solution as per my experience is to explore do-it-yourself options for applying RV roof protection, significantly reducing labor costs. So, follow comprehensive guides and instructional materials to ensure proper application. In addition, follow these guidelines:

  • Contact suppliers or authorized dealers directly to inquire about bulk purchase discounts for RV Flex Armor materials. Plus, negotiating for a better rate when buying in larger quantities can help mitigate overall costs.
  • Also, consider investing in professional training programs for RV owners interested in applying Flex Armor themselves. Learning the proper techniques can lead to cost savings in the long run and empower owners to take control of their RV maintenance.

User Experiences Related to the Flex Armor

Considering all the positive and negative implications of the RV flex armor, users have varied views about this product. In this section, I will shed light on both types of points of view people have for this RV roof protection product.

<strong>Sarah A</strong>

Sarah A. expressed positive emotions toward this RV protection product as she was concerned about RV roof being constantly exposed to various elements. Such as sunlight, low-hanging trees, and potential chemical damage. So, applying a protective layer such as FlexArmor satisfied her as it really provided UV protection.

<strong>Mr. Walton</strong>

Walton shared that his RV roof was approaching the end of its original lifespan. So he really praised the added benefit of extended roof life and leak prevention using FlexArmor. Moreover, he considered it the best investment he had made for his RV.

<strong>James S:</strong>

James S. stated that he is unhappy with this product due to its high cost. According to him, the expense of a 33-foot RV exceeds $7000 in Green Cove Springs, exclusive of potential additional repairs or modifications. It was a really surprising cost from his point of view.

<strong>Emma Z</strong>

Emma Z. raised the concern of increased weight of the RV due to applying flex armor. This made her wonder what belongings she could take out in future journeys which was very disturbing for her. Furthermore, she was dissatisfied with the limited availability of approved service centers for installing this roofing material.


How much does FlexArmor cost?

FlexArmor usually comes at a cost of about $170 for every linear foot. If your roof has solar panels or requires wood repair, the price might go up.

What is the best RV roof sealant?

Dicor Self-Leveling Lap Sealant stands out as the best RV roof sealant. RV service centers throughout the United States utilize this product due to its cost-effective rates.

How do I protect my RV rubber roof?

If you want to protect your RV rubber roof, regularly clean it with a mild detergent. Also, you have to repair any damage using a compatible sealant product.


Summing up, if you are encountering RV flex armor problems, these can be due to various reasons which include faulty roof structure, improper AC mounting, and cracks in the roof. To resolve these issues, apply a pressure-sensitive or glue-down patch to the faulty roof.

Plus, replace the damaged gasket and use a protective coating for cracks. Further, you can also opt for protective coatings to get rid of peeling and cracking. If your issue still persists, contact an RV professional for help.

So, what problems did you face while protecting your RVs with the protective coating? Share your experience with me in the comments below!

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