Rust Spots forming on rear panels

[Saxo Appeal]

Can’t believe it! Decided to wash the caravan for the first time, whilst on our holiday pitch.

Brand new 2023 caravan and already seeing rust spots forming on a rear panel purchased Oct.

This is appalling on a split new caravan we just paid just under £40k for

Will need to check our warranty but presume we have something like a 5-10 year paint warranty?

Has anyone else had this issue on a new caravan and what have you done?

 

[GaryB]

While that certainly looks like rust (ferrous oxide) the trim is aluminium and won’t corrode like that so it could be steel inclusions have got into the aluminium during extruding (not unheard of). Certainly should be sorted under warranty, I would push for the rail being replaced as if it is just cleaned and repainted it could resurface later.

 

[Hutch]

I hope your not on pitch when the photos were taken, those other vans look a bit close.

 

[otherclive]

Well I never cease to be surprised at what arises on caravans. Certainly looks like rusting and it’s random and restricted to a single member. Need to contact dealership with a view to the member being replaced. Certainly not repainted.

 

[Saxo Appeal]

I hope your not on pitch when the photos were taken, those other vans look a bit close.

No no mate. That was a photo of the caravan when it was at the dealership. The photo I took today was too large for this forum, yet the closest one was fine

 

[otherclive]

No no mate. That was a photo of the caravan when it was at the dealership. The photo I took today was too large for this forum, yet the closest one was fine

If you use iPhone or IOS you can select a smaller size photo option once you have Photos up

 

[Saxo Appeal]

Thanks @otherclive, nice tip

 

[Saxo Appeal]

As we are first time owners, looks like we have 10 year warranty on body shell

 

[ProfJohnL]

I have seen red rust spots on a caravan many years ago when the manufacturer had run out of the stainless steel screws and had used ordinary steel screws from the inside and had touched the aluminium outer skin. , however the spots were regularly spaced and corresponded with the fixings. Clearly this is not the case in Saxo's case, where the spots are random. It certainly gives the impression the area where they have appeared is not aluminium but more likely poorly painted steel.

 

[toad a caravan]

An angle grinder used in close proximity could have a similar effect by the hot metal sparks landing on the aluminium rail then rusting

 

[otherclive]

If you use iPhone or IOS you can select a smaller size photo option once you have Photos up

Here’s what you should see.

 

[Saxo Appeal]

Here’s what you should see. View attachment 6389View attachment 6390

Yes that’s what I got thanks

 

[Mr Plodd]

An angle grinder used in close proximity could have a similar effect by the hot metal sparks landing on the aluminium rail then rusting

That was my first thought when I saw the pictures as well. A bit if Super Resin Polish or similar should sort it all out.

 

[otherclive]

I read of a caravan that got rust spots on one side. They were put down as iron debris from the brakes and pantographs of trains passing the storage site.

 

[toad a caravan]

Many new cars transported by rail are covered up as OtherClive states to prevent brake dust contamination

 

[Saxo Appeal]

Well including the spot rusting, we have noticed a few other issues internally

The toilet door is shaped like a boomerang (slight exaggeration) but still bowed, the drawer under the bottom bunk bed is also bowed, and the panel which is under the main double bed has a fixing which keeps popping off. All as pictured.

 

[audiorob]

I concur with Mr Plodd and would try some high quality polish to see if it’s surface marking and will buff away. Hope this is the case as I too can’t see why aluminium extrusion should ‘rust through’ the white finish.
I think the dealer should be sorting out the internals - as you say you have invested plenty of hard earned and don’t expect to be applying DIY to sort out shortcomings.
Good luck!

 

[Saxo Appeal]

I’m not even going to touch the rust spots,

Sometimes it’s better to have the problem looked at and fixed, rather than doing something which may cause more issues.

It’s still got full warranty, so I’ll take full advantage of.

 

[ProfJohnL]

... I too can’t see why aluminium extrusion should ‘rust through’ the white finish.
I think the dealer should be sorting out the internals - as you say you have invested plenty of hard earned and don’t expect to be applying DIY to sort out shortcomings.
Good luck!

Just out of interest, If the panel involved were aluminium, then it shouldn't have red brown corrosion as aluminium Oxide is white. To find out if the panel is steel rather than aluminium, try to see if a magnet is attracted to the panel, Aluminium is not magnetic.

I fully agree the supplying dealer is liable to get all defects sorted.

 

[Mr Plodd]

Just out of interest, If the panel involved were aluminium, then it shouldn't have red brown corrosion as aluminium Oxide is white. To find out if the panel is steel rather than aluminium, try to see if a magnet is attracted to the panel, Aluminium is not magnetic.

I fully agree the supplying dealer is liable to get all defects sorted.

No- one is going to use a steel panel in a caravan, far too heavy.

 

[toad a caravan]

Or very thin (shim steel) also I assume no other trims have similar marking.The best solution I think is to take it back to where it came from...Also it may have been damaged at the factory or the trim supplier and not shown up until exposed to the elements

 

[ProfJohnL]

No- one is going to use a steel panel in a caravan, far too heavy.

From the pictures the area is a slim infill panel. Rather than dismissing the idea perhaps allow the OP to test it if they want to. Aluminium simply should not produce red rust unless it has been compromised by a feric component.

 

[otherclive]

No- one is going to use a steel panel in a caravan, far too heavy.

In these times of supply chain problems I wouldn’t rule anything out. Thin sheet steel painted could be one possibility. But stainless wouldn’t occur to a maker 😱

Very interested to hear what Saxo finds out.

 

[GaryB]

As I said earlier, steel Inclusions in aluminium extrusions aren’t common BUT do happen. I work in the cable accessories/cable joining industry and some of our bolts are made from hexagon aluminium extrusion. 15 years ago we had “rusty” aluminium screws and it transpired that the billet used to make the extrusion had steel contamination in it. Unlikely in the OP’s case but “anything’s possible”.

Whatever the cause, it’s frustrating in a new/expensive caravan.

 

[Saxo Appeal]

Just to update this,

I have asked why there is rust forming but no answer.,.however!

Caravan is booked in to the dealership to have new rails fitted on both sides of the caravan, plus a few extra snags.