Lunars poor design

[Richard Avensis]

Hi , just sharing info about my 2013 Lunar 490/4.
Today I had to remove the rear light / bumper panel and discovered a rather poor design . The aluminium rear panel does not run down to the bottom , but instead , stops roughly 4 inches from the bottom. In the photos you can see where the butyl tape failed and has allowed rain water to enter .
If the upper panel had been fitted to overlap the lower , then the water could have dripped off . The rear light panel had never been sealed at the top and a local caravan engineer assumed that this was because the back panel ran to the very bottom .
This caravan had previously a new bathroom fitted but the true nature of the leak was never repaired. I am now repairing the floor as water has entered at this rear panel , cassette toilet door and also a small crack in the corner of the shower tray.
Two weeks ago I had booked the van with this engineer who was going to repair the floor and fit a new water heater for £950.
At that time he had discovered the leaking cassette door . I later decided on doing the repairs myself.

 

[Hutch]

Richard,thanks for this Forum thread, and I think this is the type of things things the forum is usefull for. It will help others as they repair their caravans, carry on with this . Great.

 

[Hutch]

I have just re read your posting, about the shower. Tray. Recently I have used Capt Trollys, crack sealer,, in our shower at home, On using it seemed weak, but it worked well. £10 well spent.

 

[Richard Avensis]

I was going to try and find a replacement tray for this Lunar , but after removing the tray and realising who flimsy they are I decided not to bother . A good friend has offered to make one from stainless which will last for ever and ever .

 

[Dustydog]

Blame the cost accountants and the quest for shedding weight. Lunar always boasted theirs were the lightest. You can see why! Whilst a poor design feature the use of sealant at the factory would have helped as you point out.
Well done with your progress and updates👏👏

 

[Mel]

Thanks for the updates and well done with your project. Keep your friend well supplied with thank you gifts as, given the breathtaking quality of Caravans; you will need their help again.
Keep us updated
Mel

 

[Richard Avensis]

Hi , I resealed the rear lower panel with fresh butyl tape , a row of small stainless self tapers and sealed over with Sikaflex 522 . Refitted the light panel and side awning trims and sealed the top of the light panel with 522 .
Not the sort of job you would want every Saturday. Removing old butyl tape must be the worst job in the world ..

 

[otherclive]

I have just re read your posting, about the shower. Tray. Recently I have used Capt Trollys, crack sealer,, in our shower at home, On using it seemed weak, but it worked well. £10 well spent.

A useful addition to any toolbox is Captain Tolleys.

 

[Hutch]

A useful addition to any toolbox is Captain Tolleys.

I was surprised at how many applications you had to make, and time lapses between applications, but it all went well. Save having to replace the shower tray.

 

[otherclive]

I was surprised at how many applications you had to make, and time lapses between applications, but it all went well. Save having to replace the shower tray.

I suggested it for the possible leak on the thetford locker door. Cheaper than £80 fir a new door.

 

[Beachball]

Sounds like the plan has been well thought out and you are doing a good job with aid from a friend to complete your project. Looking forward to further updates on this .

 

[Richard Avensis]

Thanks , I never wanted a project .I bought this as I thought it was mint and a bargain . If it wasn't for bad luck I would have none. I have made pledge to the wife and kids that I can turn this around. Have already booked a park in August. Plenty of time ..

 

[otherclive]

I'm sure that it will come together in good time for your holiday, and your wife and children will really enjoy the experience. Hopefully the first of many to come.

 

[Raywood]

I was going to try and find a replacement tray for this Lunar , but after removing the tray and realising who flimsy they are I decided not to bother . A good friend has offered to make one from stainless which will last for ever and ever .

We had the shower tray crack. We were able to get it repaired with a thick additional coating that looks to have worked well and provides a better non slip finish.