Alu-Cab Gen III Expedition tent leak fix and overhaul

My Alu-Cab Gen III Expedition rooftop tent developed a significant leak after only 3 years. I identified the cause of the leak, and took the time to fix it right. That fix lead me to overhaul the entire tent including rewiring, new flooring, disinfection, and more.

To fix your own leaky Alu-Cab rooftop tent, watch this tutorial to see step by step how I repaired my tent to be better than new.

Most of the items used in these repairs (US sources for purchasing)

-----------------------------------------
Leak sealing
-----------------------------------------

SikaFlex 221 black multipurpose adhesive/sealant
- used for the leaking tent roof seams
- US purchase: https://amzn.to/3HQkYNz

Permatex 81158 black silicone adhesive sealant
- used for any mounting bolts/screws you may have put into your tent top/sides/underneath
- US purchase: https://amzn.to/3pdPmuN

Crimped wire wheel
- used on an angle grinder to clean any paint/coating from the tent roof seam
- US purchase: https://amzn.to/42cLfOj

Frog Tape
- for masking lines for the adhesive application
- US purchase: https://amzn.to/42cGPHi

-----------------------------------------
Electrical
-----------------------------------------

National Luma touch LED lights (white/yellow)
- what I use for my interior dome light, and lighting the truck bed space underneath my tent
- Global site: https://www.nationalluna.com/product-...
- US purchase: https://www.equipt1.com/products/touc...

Dual quick charge USB ports
- used 2 of these inside the tent into the sides of the factory power box
- US purchase: https://amzn.to/3VGqOGY

80 AMP inline circuit breaker
- used inside tent for wire from Anderson plug to tent power
- US purchase: https://amzn.to/42eDTcW

6-way fused distribution block
- used inside the tent after the circuit breaker to distribute power to tent lights and USB charging ports
- US purchase: https://amzn.to/3M3T1UT

Various gauge insulated positive/negative wire
- for all of my rewiring of the tent power box and leads going out of it to my tent lighting
- 12AWG for power supply wiring, 16AWG to National Luna lights
- US purchase: https://amzn.to/44GCkX9

6AWG flexible insulated welding cable
- used for power cable from tent Anderson plug to the tent's new circuit breaker
- US purchase: https://amzn.to/42cLfOj

Anderson battery quick connect plug heads
- used to replace tent's factory plug, and also to make a new Anderson to Anderson power supply cable from my truck bed outlet
- US purchase: https://amzn.to/3LzD1Zi

Anderson water resistant power port
- installed into my truck's bedside direct from truck battery to provide tent power
- US purchase: https://amzn.to/3NNEqhV

Solder and seal heat shrink butt connectors
- used for my internal tent wiring to waterproof and solder wire connections
- US purchase: https://amzn.to/44GFXwf

-----------------------------------------
Foam flooring and mattress
-----------------------------------------

Both from Foam Factory, Inc. in the US
https://www.foambymail.com/

Polyethylene Foam Roll
Density: 2LB Density
Size: 1/2" Thick x 60" Wide
Increment: Lineal Foot
Color: Charcoal
- used as the new tent floor cushion/insulation underneath the mattress (no adhesive needed)
- https://www.foambymail.com/product/po...

Mattress, HD36 Foam - HQ (M)
Dimensions: 4" x 48" x 82"
- My main mattress, used on top of the polyethylene foam on the tent floor
- https://www.foambymail.com/custom-foa...

-----------------------------------------
Other items
-----------------------------------------

Abrasive flapper discs
- Used the 120 grit disc with an angle grinder to strip the bottom of the tent after removing the factory rubber floor
- US purchase: https://amzn.to/3NJjpVz

RMR-141 disinfectant and cleaner - 128oz
- used to remove mold and mildew from tent hard surfaces and fabric
- US purchase: https://amzn.to/3M4NXQb

#alucab #alucabgen3tent #alucabtentleak #rooftoptents #rooftoptentleak #tentleaks #tentcamping #alu-cab