Some solutions which may help others. The damp warnings in the toilet area that I had at the last service have now got the all-clear at the latest service, so success!
Problem: I had damp on the wall between the sink unit/cupboard and the toilet cistern and on the floor.
Solutions:
I removed and resealed the toilet filler hatch and the toilet cassette hatch (& the battery box hatch as I was on a roll!). Cleaned and resealed with Sikaflex 522. The original sealer seemed very sparce in places.
I changed the toilet cassette hatch rubber seal.
In working on the cassette hatch I noticed that the push-button without the lock wasn't engaging properly. It looked shut, but you could prise it away from the caravan with your fingers. I took the catch apart and reassembled it correctly. I believe this had been faulty since manufacture. Push both sides of your cassette door in to ensure both catches click into place and then see if you can prise the door back (gently). This flex (front catch) will have allowed water in while driving in wet weather as well as general dampness when stood.
I discovered my sink tap was weeping occasionally at the swivel joint. This allowed water along the back of the sink worktop and down the wall between the sink unit and the toilet. Up to that point, I just put the wetness down to water splash while washing. I tried to find a replacement valve that would fit, but they all leaked. Replaced the tap. No leak.
I removed the toilet to check the flush mechanism wasn't leaking underneath. I attached it to a 12v battery on the drive and undertook tests. All ok. However, removing the toilet exposed black mold on the wall behind the cistern. The cistern has a rubber seal around its edge and was stopping the damp escaping/drying out. A nail brush and domestos removed the black staining. With toilet and hatch removed, I dried the whole area with a hot hair dryer and then left to air for days (with the outside of the cassette hatch hole loosely covered to weather proof the area).
When caravanning in the cooler months, the toilet cistern has condensation below the water line. I can't recall, but I think this goes once the freshly filled cistern water acclimatises? Anyway, a towel placed between the back of the toilet and the base of the cistern catches any drips while this is occurring and stops water on the floor.
Summary: I think the faulty cassette catch was my main culprit, followed by the occasional weeping tap and the cistern condensation. The damp problem is resolved.
Hopefully the above may be of help to others and I appreciate may have been covered in parts elsewhere. Some pics below.
As I found out when cleaning my rather grubby cassette compartment soon after getting my van s/h (the previous owners were mucky buggers throughout! - but mud and leaves etc. transferred from cassette that must have been stood in a muddy puddle regularly!).
The cassette compartment is not sealed from the inside of the van in any way, any water getting in there will spill out onto bathroom floor, and/or soak floor/wall if left! If the external door is not watertight for whatever reason, failed catch or seal, just a bad fit, frame sealing failed etc., then rainwater can get in and become a damp problem.
Noted. I would also recommend ensuring the cassette is dried after that drag there and back across wet grass to the emptying point. Only a dry cassette goes in my locker :-)
To quote Thetford user manual "To prevent water damage to your caravan or motor home, ensure that you don’t travel with a full flush-water tank or with water in the bowl"
I've always left some in the tank for on journey and 'soon as I'm pitched' use, but never close to full, and never had a problem. As I use the blue 'both tank' fluid, any leakage would be obvious.
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