How to repair a polycarbonate roof on a Gazebo

 

 

Repaired polycarbonate roof on a Gazebo

Damage to twin-wall polycarbonate roof on a Gazebo

The roof on our Gazebo was covered with small holes and quite a few cracks. I searched the internet in vain for instructions on how to repair the panels and finally decided to come up with my own repair. I have no idea how long this will last, but at least it's repairable, if necessary. And of course it will be probably necessary again at some point. 

List of materials:

Gorilla Black Duct Tape, 1.88"

Gorilla Crystal Clear Duct Tape, 1.88”

White, water-based primer

5 Gal Liquid Rubber Color Waterproof Sealant 

Total cost approximately $325

Step 1

Clean the panels with soap and water, dry and then clean again with alcohol 

 Step 2

 Tape the panels with clear duct tape

I used clear duct tape because I didn't want to block all the light coming through the panels

Step 3

Tape the joints with black duct tape

 

You'll note that I completely covered the lower panels while only doing spot repairs on the upper panels -- mainly because I couldn't reach far enough and most of the damage was on the lower panels anyway.

 

Step 4

Apply Primer

 

Step 5

Apply Many Thin Coats of Liquid Rubber

You have to put on thin coats and then wait 8-10 hours between each coat for it to cure. It would have been a lot easier to spray on the Liquid Rubber, but that requires a heavy-duty paint sprayer. How many coats of Liquid Rubber are enough? Well, that depends on a lot of things; like do you get a lot of hail, how much you want to spend on Liquid Rubber, or how much time you want to spend doing this. I put on about 10 coats already and I may put on a few more while the roof is still clean. More coats should equal a longer life and fewer repairs. 

If you are wondering why I didn't just replace the polycarbonate panels, this is why. $376.44 for just one side and you'd need four of these kits for a total cost of over $1,500.

Update 5/4/2023

 

This is what the repair looks like after three years and without any cleaning. It is completely intact and there are no signs of deterioration.

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