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How to fix a leaky caravan?

Newbie here. I bought a 1993 Jayco Sprite caravan. As it has two single beds, I decided to take them out to make a double bed. I noticed a wet patch as I started pulling the beds apart. To my sour joy the girl is leaking grrrrr. I would like to know a good sealant for inside and outside the van. Thanks team

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EricL

Hello @Peppers

Welcome to the Bunnings Workshop community. It's sensational to have you join us, and thanks for sharing your question about your caravan.

I suggest having a look at Selleys 290ml Grey Storm Waterproof Gutter And Roof Sealant. It can be applied to various substrates and can be painted over.

Let me call on our experienced members @twocutekelpies and @FloTheCaravan for their recommendations.

If you need further assistance, please let us know.

Eric

Peppers

https://www.workshop.bunnings.com.au/discussion/comment/52136#Comment_52136

Thank you for your response Eric. I truly appreciate it

twocutekelpies

Hi there @Peppers, what a shame to find that.

I'd recommend resealing the entire caravan which unfortunately involves taking off the trims, cleaning the old sealant off and resealing with new. Same with the windows. It looks like someone has smeared silicone over original sealant in the hopes of fixing any leaks and it hasn't worked. Silicone rarely sticks to other sealants and usually only leads to mess and failure ☹️

Most sealants generally only last around 5-10 yrs and most owners don't do full reseals until they find leaks and by then, they find more damage hidden inside the walls/roof as you have found.

Bunnings sells a silicone remover which might be worth trying to get that mess off, I can't comment on its effectiveness as I've always used a nylon wheel on a drill or wire wheel on a grinder if I need more aggressive means of removal, my method takes paint off though.

As far as what product to use to reseal, there have been many heated debates in the caravan diy community, what to use - silicone, polyurethane, mastic? There are quite a few pros and cons for each. I have used each of them successfully, my preference is Sikaflex Pro for the trims/j rails because it's budget friendly (sausage rather than cartridge is cheaper), available local to me, paintable and I've got it down to a fine art with application and clean-up. I like mastic caulking tape for the windows with a bead of Sikaflex Pro to finish off because I can take my time fitting the windows without the mess.

For sealing inside, I'm a fan of Crommelins Waterproofing paint, it can be used of roof joins on full vans but have heard not great with poptop roofs, too much flex. I've used that paint and Crommelins fabric on a few inside joins and on top, when used outside, it can be painted over with acrylic paint.

Good luck and I hope that you post your finished project.

I won't say resealing is an easy job but I've fully resealed 5 caravans now, my motto is do it once, do it right, band-aid fixes don't work. If this grandma can do it, anyone can 😎

Cheers

Shelley

Peppers

https://www.workshop.bunnings.com.au/discussion/comment/52139#Comment_52139

OMG, I am truly thankful that you have shared such amazing knowledge to help me through. I’ll re read your comment to process everything and look into what you’ve recommended. You will see that I will need to take the framing off as it is water damaged. I was going to take the window out so I can clean and reseal that as well.

LizzieCro

https://www.workshop.bunnings.com.au/discussion/comment/88225#Comment_88225

Hey Peppers,

Where are you located? Maybe someone will see this and can offer to pop over and chat. I'm in the Illawarra, NSW and would be happy to do so.

Oh, and just take Shelley's advice. She knows stuff..... LOTS of stuff!

Cheers, Liz.

LizzieCro

https://www.workshop.bunnings.com.au/discussion/comment/52139#Comment_52139

Hi Shelley,

You're right, resealing isn't an easy job, but it is really satisfying! 🙂

Cheers, Liz.

Peppers

https://www.workshop.bunnings.com.au/discussion/comment/110050#Comment_110050

Hi lovely, I am in Brisbane. Being among this group helps a lot. I have used a lot of the amazing ideas provided by you all. I don’t have the option to have my van under cover. It’s out in the raw weather. However I am getting there. Slow but surely

EricL

https://www.workshop.bunnings.com.au/discussion/comment/88695#Comment_88695

Hi @Peppers

Please keep us updated with your progress, we would love to follow along as you rebuild your dream caravan.

Eric

Peppers

https://www.workshop.bunnings.com.au/discussion/comment/110058#Comment_110058

Hi all over the week and weekend I took the front window out to reseal.. that was not easy as a screw refused to budge. I managed to get the window out, clean it up and put it back in. What a mission. It wasn’t a great job as it decided to storm down on me. So I had rush everything and seal the window. It looks terrible. I will need to do it again. I rushed as I don’t have the option to be under cover grrrr

EricL

https://www.workshop.bunnings.com.au/discussion/comment/122383#Comment_122383

Hi @Peppers

Thanks for the update, I propose looking into investing in an OZtrail 3m Hydroflow Anti Ponding Non-Permanent Gazebo to keep the work going along with some OZtrail Base Pods Gazebo Weights Kit - 4 Pack to keep the gazebo down.

Eric

twocutekelpies

Thanks for the update @Peppers, keep going, you'll get there.

I second Eric's suggestion of a gazebo or something to cover. My first reno/rebuild was a 23ft Viscount, no undercover area for it either, I managed to get a very large tarp to cover the whole van then just lifted a section at a time with tent poles to get access.

I had to do the same with my second, 15ft Viscount, I used pool noodles to keep the tarp off the trims while the sealant set.

Hopefully the weather will be on your side now for a bit, so you can get the job done.

LizzieCro

https://www.workshop.bunnings.com.au/discussion/comment/122383#Comment_122383

Hi @Peppers ,

Great to see you in there having a go! I agree with Eric, a gazebo/marquee often helps in that situation. If you do buy a gazebo get one with walls.

Regarding the screw, you’ve probably tried this for stubborn screws, but get your Philips head screw driver, slot it into the screw head and give it a few hard taps with a hammer, then try to unscrew it. Repeat if necessary. I also find, as odd as it sounds, sometimes trying to tighten it instead of loosen it will break that grip. Obviously don’t keep tightening it, but give it a try. Be aware that if you need to replace the screws they are Marine Grade 316 screws, not just any sort. I had to buy mine from a specialist fixings shop as unfortunately Bunnings didn’t have the required gauge and length of those screws. They do, however, have a good range of 316 screws for other parts of the van. Also, when reinserting the screws, make sure you put some sealant in the hole before the screw.

Looking at the damage to screw and metal in your image, it looks like you might be using a wire brush??? Not a great idea at all. Aluminium is very soft so scratches easily. Instead use a Josco nylon brush attachment on your drill. They’re in Bunnings in the tool section, and look like red anemones. The nylon wheels will make light work of cleaning the old sealant off windows trims/J rails, etc, and you’ll be singing its praises like the rest of us.

LizzieCro

https://www.workshop.bunnings.com.au/discussion/comment/122383#Comment_122383

This is the Josco nylon wheel, and Sikaflex Pro which is a great sealant for the van.

I have to say I did soooo much research before I started pulling apart my first van. I highly recommend you take your time and ask the questions, here snd on caravan renovation forums, otherwise it may become a disappointing and costly exercise. You can do it! Just get the info first and really enjoy the experience!

Peppers

https://www.workshop.bunnings.com.au/discussion/comment/53059#Comment_53059

Thank you for the tips. I appreciate it. I have bought a gazebo and a very large tarp. I will now find somewhere level as my place is not. Below is not the best start to doing anything safe. This is me doing prep work, jammed between a work van, ladder on a piece of wood to keep it steady, my gear on the roof top of the van lol and the end product of me waterproofing it

Peppers

https://www.workshop.bunnings.com.au/discussion/comment/130322#Comment_130322

Thank you for all the suggestions. That screw tested me big time. I did everything you mentioned and more. I even bought screw extractors. No luck, so a friend came over ( a builder) said to cut it off, which I did. The damage on the trim is from me trying to get the screw out. In regards to removing the silicone. I bought Josco nylon wheel brushes. What a game changer. It is this forum I get the help to help me along. Thank YOU ALL

LizzieCro

https://www.workshop.bunnings.com.au/discussion/comment/135253#Comment_135253

Fabulous! Whatever it takes.

Once you've removed the sealant with the nylon wheel, make sure to wipe it all over with acetone (Bunnings paint section, near the turps, etc), to remove any unseen residue from old sealant. Any residue will interfere with you getting the perfect seal once you put on the new sealant, as they're not compatible. Do it once and do it right. It's a pain having to revisit jobs.

AlanM52

Rotting timber is a common problem with RV's

Water finds its way under the cladding and rots the timber.

Many of the older RV's have lots of silicon on them.

The last one I did had water coming in on the inside of both sides.

Roof lining was peeled back to reveal rotting timber rails.

Had to call upon a tradie mate with a vehicle that can carry long stuff and got two lengths of timber from Bunnings Notting Hill.

Rails are square and odd size so we had to carry my table saw outside to rip down to correct size.

New rails were installed and roof lining glued back down.

Job was done Dec 2019 and owner reporting that job still OK.

However two years later she started leaking around the air conditioner so we had to remove that are replace timber in that area and reseal.

Even if you patch up what's there it's likely she will start leaking in other places.

Looking at the photos I think you are in for a full roof restore to replace all the timbers and possibly new cladding.

I suggest you do a Google using 'EPDM Rubber Roofing for RV's'.

Cheers

LizzieCro

https://www.workshop.bunnings.com.au/discussion/comment/135253#Comment_135253

Hey @Peppers ,

Respectfully, I disagree with Alan's thoughts on having to replace all roof timbers and possible cladding. I don't think enough information can be gleaned from the photos to determine that, and your cladding won't be affected by water ingress as it's aluminium, so no need to consider replacing that. It is a pop top after all, so the roof isn't actually connected to the van, except by struts and a vinyl skirt. It looks like it may be leaking where the aluminium is at the base of the pop top, but even so, I don't imagine all is lost.

If you methodically work your way around the van, removing trims from the corners, removing windows and door, and remove all traces of past sealant and replace it with new, you'll know your van is sealed properly. Additionally, rake out the joins/folded seams in the cladding, clean it up with acetone, then reseal those too. Very often those aren't sealed at all. It looks like the seam at the top, front of the van is the likely place where water's getting in. There's no point in doing half a job. As Alan says, if you do 'spot' sealing, even if you patch one spot, it'll be likely to leak somewhere else. Sealant on vans should be totally replaced every ten years. Given your van is a 1993 model, it should have been completely re-sealed twice by now, but obviously previous owners have just added more sealant onto the problem areas, which would never work.

Keep the faith, and just slowly keep going. There's no point in rushing blindly into it in the hope it'll all work out. You can't cut corners if you want a good outcome. You'll just end up going back and having to undo and re-do the work you've done. There is no joy in that.

You'll be right, love. Just take your time and research, research, research.

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