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Topic: Advice with DIY damp repair

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roundthecampfire

28/12/2023 at 9:38pm
Location: Mid Sussex UK
Outfit: Coachman Amara 640 6

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Hi all,

Hoping to tap into some of the wisdom of the group :)

I'm in the process of repairing some fairly significant damp on the front panel of our 2011 Coachman Amara 640/6. I've taken the inner blinds off, taken the windows and window seals out and stripped back the rotted plywood.

I've uploaded a couple of pictures, one with the blinds off before I started on the plywood, and another with the rotten stuff ripped out. I think I've found the source of the leaks, there are some cracks along the window rail which is about where the water marks on the window started.

I'm thinking I should strip out the whole board, was thinking of using a multitool to get through the more solid material at the top. Feels like it's screwed down from the top but I can't get to the screws. I plan to replace the rotten board with 18mm marine ply and then buy some 3mm board with the right design on it to finish the inside.

The stuff I'm not decided on are:

- Should I bond the replacement board to the ABS of the front panel? Doesn't seem to be bonded at the moment but can't work out if that's due to the damp
- Does my approach above sound about right?

Really interested to hear other people's experiences, thanks in advance!

George

Post last edited on 28/12/2023 21:58:33

roundthecampfire

28/12/2023 at 9:38pm
Location: Mid Sussex UK
Outfit: Coachman Amara 640 6

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roundthecampfire

28/12/2023 at 10:00pm
Location: Mid Sussex UK
Outfit: Coachman Amara 640 6

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I've had a read of some of the other posts in this section of the forum and thought I should mention that our Coachman seems to be constructed differently than most, as there's no framework around the windows. It seems to be a single sheet of 23mm ply with the printed plastic layer on the inside.

I've had a look and can only find 3mm decorated panels so that was why I was going 18mm + 3mm to be somewhere near the original construction.

Interested to hear everyone's thoughts and thanks again!

Pickled Onion

29/12/2023 at 11:00am
Location: Near Alton Towers
Outfit: Bailey+Burgundy+S7+H

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Luckily, I've had no experience of doing a front window repair,....yet. Therefore my expertise is limited but I don't think the ply was ever bonded to the ABS front so some meaty half lay scarf joints onto the old but sound ply should suffice.

The main thing is finding the root cause of the problem and the over-window support strip is a very common failure point. Probably the fixing holes were non existant or too small at assembly, the resulting strain splits the ABS over time. The multi-tool is a wonderful bit of kit for caravan panel repairs, I've used mine to do the underbed floor and to replace wall and ceiling parts in both front top corners.

Dave

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Never argue with an idiot, they will drag you down to their level and beat you on experience.
Mark Twain.

roundthecampfire

30/12/2023 at 4:45pm
Location: Mid Sussex UK
Outfit: Coachman Amara 640 6

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Hi Dave

Thanks for the response. I ended up ripping the whole sheet out as it was wet to pretty much the height of the windows. Was a battle as the screws were all driven in from the outside before the outside skin was installed, so required some multitool and reciprocating saw action before it came free.

I've now installed a couple of battens in place of the original brackets to reattach the new front panel. I've found the source of the leak, as you mentioned it was from vertical cracks above and below the window strip screws. One was about 2mm wide! I've bought a plastic weld kit off Amazon and welded all of the bigger cracks, and smoothed off with a soldering iron. Started rubbing it back with 40 grit but ran out of light today. Tomorrow I'll finish that off and then get some plastic filler for the next stage.

Learning lots of new skills with this one! I'll post some more pics for anyone else facing the same sort of thing below.

Front panel removed, pressure treated batten installed either side to receive new panel:

Plastic weld of the worst crack:

The other thing I've noticed is there's pretty much no insulation on this panel at all - so I'm thinking of maybe using 18mm ply and then getting some thin insulation board and sandwiching that between the 18mm ply and the decorative board on the inside. I've seen window seals that are wider and would support it. Still not decided though.

Pickled Onion

01/1/2024 at 11:32am
Location: Near Alton Towers
Outfit: Bailey+Burgundy+S7+H

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Well done you,

that's a cracking job, (no pun intended with the window frame) and one I'm sure that you are proud of.

It's another fine example to others who find themselves in a similar predicament, and shows just what can be achieved with a few tools and a bit of effort, a major repair job at at budget price.

Enjoy the fruits of your labours mate.

Dave.

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Never argue with an idiot, they will drag you down to their level and beat you on experience.
Mark Twain.

Fiona W

via mobile 01/1/2024 at 4:12pm
Location: Ayrshire
Outfit: A2DS+Nuevo

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Thinking about the insulation, you can get rolls of flexible stuff like “silver screen” material, or the pieces that go behind radiators; might be easier to work with, and certainly lighter weight.
Looks like a proper job though: well done.

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Toad acaravan

via mobile 19/1/2024 at 9:03pm
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Have you considered the Ali/foam rolls used under laminate flooring (approx 4mm thick)...Gary

Tpdaviso

via mobile 01/9/2025 at 12:35pm
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I may have to go this route for a fix on a 2010 pastiche. I’m wondering how you managed to secure the new plywood to the old solid plywood above below and to the sides?! I read about a scarf joint above, but it doesn’t look like you put one or 2 (I know nothing about scarf joints) in. Any chance you can post a finished product?! Did you end up covering it with 3 mm ply?

A few more questions, did you re use your window seals? I don’t see any cracks in the abs on my caravan so I think it’s a failed seal that’s caused a slow degradation of the wood. But I’ll have a better look tomorrow. How long do you predict the job took?!

Thank you in advance!!

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