How to fix or replace Jayco caravan windows?

[Peppers]

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 

 

 

 

 

 

 

  

[JacobZ]

Hi @Peppers,

Allow me to start the conversation by tagging in some of our keen caravan renovators, such as @twocutekelpies and @Peggers to see what they think.

I can't say I'm an expert on caravans, having never worked on one myself, but the aluminium cladding certainly does look a bit rough around the edges. 

Have you considered what kind of window you will be putting back in? Does it have a flange around it?

I imagine installing a flanged window that covers the rough edges would still look good, and ensuring it is well sealed will help prevent further rot.

Based purely on opinion, I think it is salvageable, however, I will tag in others to see what they think - @Nailbag, @Noyade and @Dave-1.

Jacob

[Noyade]

Sorry @Peppers 

Thanks for the tag @JacobZ .

But I have no experience with caravans - other than angry memories when the Hume Highway was not dual carriageway. 

😕

[Dave-1]

Afternoon @Peppers 

Mmmm I went straight to a flashinga round the window to cover the rough edges and then @JacobZ used the correct term with flange I would suspect that a new window will have some overlap from the outside for this very purpose. I think I would leave the aluminium as is and have a look around at what type of caravan windows there are.

Dave

[Nailbag · Accepted solution]

Hi @Peppers 

I have repaired quite a few caravans in mine time and all Jayco's with some form of water leak, ingress or loose connections of some form.

The first important step is to repair the timber frame. Cutting out the rot, applying wood hardener, bogging the missing sections and reshaping. Then apply a good base primer.

from the photos I don't think you need to replace the cladding. Just ensure when installing the new window that it's properly flashed and siliconed into place. I have used this product to basically re-seal areas that may be damaged that extend past the window frame.

Nailbag

[Peppers]

I appreciate your comment. I will definitely do what you have suggested. I have replaced the rotted frame that can be seen in the pics. I’ll also get some wood hardener. 

[Peppers]

You mentioned bogging. What did you use. I was going to use a waterproof membrane that I have used on the roof of my caravan as a back up as well to waterproof around the window. I will get the weather aluminium flashing and wood hardner

[JacobZ]

Hi @Peppers,

I can't say for sure what @Nailbag used in the past, but Builder's Bog is perfect as long as it is used on the inside of the window and doesn't get exposed to water.

Let me know if you have any further questions.

Jacob

[Nailbag]

Hi @Peppers 

sorry I did mean Builder's Bog as @JacobZ picked up and is ideal to replace the rotted timber sections.

Nailbag

[Peppers]

Hi you mentioned you used CA weatherf flashing. Do you have pics as I don’t know how to use this