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Looks a mess I have pulled the front window out of my 1993 Jayco caravan as it was leaking. To find this horrible mess grrrrr. I’ve come here for suggestions. The first 6 pics below are what the window looked like when I took it out. The silicone was terrible. I noticed the silicone had trapped water in parts of the window which rotted the frame. I have cleaned off the old silicone. So I’ll take them out and replace them. The last pics are the end product.
Questions
Should I replace the aluminium cladding, or can it be repaired
HI @Peppers
This flashing should work which is the same @JacobZ linked. It's one;y .3mm so it can easily be cut with sharp scissors. I use these ones which are a great little pair of scissors you can use to cut all sorts off materials and they stay sharp.
You will need to make little V-style slits as you go around the winder frame corners
Nailbag
Hello @Peppers
Don't loose hope, these setbacks are to be expected in the D.I.Y game. Things break down unexpectedly and they need to be repaired. It would be better seeing them now rather than later when all the parts are attached and your wall is fully covered up. My best advice is to replace the broken piece with a similar piece. I also recommend using the same fixings that the piece was using screws/ blind rivets or a combination of the two. It is not necessary to use a nail gun for your window repairs.
Let me call on our experienced members @twocutekelpies and @LizzieCro for their recommendations.
If you need further assistance, please let us know.
Eric
Hi Peppers,
Don't feel discouraged. Things go wrong and they're all fixable.
When you say 'parts of the caravan framing came undone' do you mean the actual framing inside the caravan wall? If so, I'm assuming a piece of horizontal timber fell down?? Nail guns aren't suitable for this work, as you'd easily puncture your aluminium. Shelley @twocutekelpies would probably be able to give you the best advice on this, as she's rebuilt many van frames. Could you take some photos of what's happened and post them here? It's difficult to know how to advise without seeing the actual problem. I imagine using screws would be best if possible, and, if necessary L-shaped brackets to join vertical with horizontal, but it all depends on how much access you have.
If it's the window frame which has come apart, that's held together with 316 Marine Grade cup head screws. You can just re-use the original ones if the threads are good, or take a couple with you and buy the same again. I had the same van you have, so here's a photo of my window. You can see that the main frame has screws holding it in, but those wedge shaped black parts (I can't recall their name), are riveted in. Rivet guns are easy to use and pretty cheap. Bunnings have them in the Tools section.
You'll be right mate. Just don't rush it. It won't do you any favours.
Hi @Peppers
Like @LizzieCro, I'm going to assume the timber frame is falling apart. I've had to reconstruct the timber around windows before after it had completely rotted away. In my old vans, the timber framing was originally stapled together and 30mm thick, which is quite hard to find now so I used 12mm and 18mm meranti, both 30mm wide to re-create the frame. I stapled and screwed the new frame together and used the aluminium opening and the window to help guide me to sizing, you're lucky that you still have original timber to guide you.
If you need to re-make the curved corners, this can be done with a jigsaw and following the below order of cuts so that you're not working with tiny bits of wood.
From your other window post, I can see that your cladding has been fastened to the timber frame with narrow crown staples, this was quite common and not unusual for them to rust out. You should be able to use side cutters or similar to cut them off to remove the rotten part of the frame ready for replacement.
I use air staple guns - narrow and wide crown, these are also available in 18v but if you don't have them, don't rush out and get them unless they'll be used for other projects as well. Frames can be screwed together and cladding can probably be tacked on with small nail tacks.
You can replace the plastic moulding that covers the frame from inside, most caravan repair shops sell this, it's much softer and more pliable that the angle at Bunnings, don't kink it though because it's impossible to get the kinks out. This is best done before the window goes in but after the internal lining goes on but I can appreciate that you need to get the window in and resealed. This may make it harder down the track but not impossible. With the window still out, it is easier to cut the internal cladding to size and router around the frame to make it tidy.
The plastic moulding can be stapled in or screwed in with flat stitching screws (Bunnings has these in 13mm white)
The moulding has to be pushed right in against the frame all the way around or the window won't fit back in.
I like to put the window in without sealant (only a few screws needed to hold in place), then use painters tape to make clean up later on a lot easier
I have had many defeated days and walked away for a bit, glad to hear you're moving forward and not letting it beat you.
Good luck and keep at it
Shelley
I noticed that this part (framing) came off when I put the window in. I had to tear away some lining that put in, hence it looks horrific
The blue arrows show what framing needs to be replaced as that is what came away. The green arrows is what I put in as it was rotten.
This area gets wet. I have no idea where the leak is coming from. I need to replace this area
Hi Shelley, thank you for sharing with me. It has tested me, but I am determined. Looks like I will need to replace the timber framing and be confident that it will stay in place when I take it on the road, once it is done. I need to buy more plastic window moulding, and make sure it is tight as a whistle so the window goes back in and doesn’t leak. (Fingers crossed). I have an 18v cordless nail gun. I hope this will work. I have a pop top, do I need to prop the roof while I sort the framing. Here are some pics of my nightmare
