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I’d got a few little jobs still outstanding from our big clean a week or so ago. The big one was to repair the front window. When we were cleaning the caravan I noticed that the bottom edge of the central window was starting to separate. After some lengthy procrastination I’d have preferred to replace it but given the hefty price tag and the “It will be January next year at the earliest before we can get you one” type answers from suppliers and removing the window and shipping to off to a company for repair would cost almost the same as a replacement.

It can’t be beyond a diy task to repair. I did a bit of searching for information relating to repairs and one name kept popping up as the manufacturer of the product used to bond the two sheets together…Bondrite Adhesives Ltd.

After reading through Bondrite Adhesives Ltd website a couple of times to work out exactly with adhesive I’d need I ordered their WC112 acrylic adhesive. The 50ml size was £12.10 plus shipping and VAT bringing the total to £20.52. It arrived within 24 hours of ordering, was really well packaged and came with a detailed technical sheet and guidance notes.

I’m not going to do a blow by blow account of how to repair a delaminated window… as I don’t know if this is even going to work, but my first step was to support the window as flat as I could. The standard recommendation is to remove the window lay it on a flat surface and go from there. I didn’t want to remove the window as all I had to repair was the lower edge.

Improvising I used two stands with a cross beam clamped between them to hold the window horizontal. This should take any flexing stress caused by the window stays out of the equation…. Hopefully!

To hold the gap between he two sheets I used three long needles from syringes… this allowed me just enough wiggle room to slide some blotting paper with a bit of isopropanol alcohol to clean out any contaminates. I’d already tested this to make sure it was safe and it does evaporate very quickly.

You are advised to lay down a 5mm bead of glue… as this was going to be difficult between the two sheets of partially bonded plastic I opted to use a wide bore syringe needle on the glue bottle which allowed me to squeeze glue into the gap… it was a bit fiddly but I managed to achieve what I thought would be the right amount. Sliding the three previous inserted needles out to allow the sheets to come together I used some fairly light clamps to hold the pieces together while they cured. Bondrite do caution about NOT using an excessive clamping force as it can lead to crazing of the sheets.

The data sheet advice is that handling strength is achieved after about 3 hours at 20 deg C. I covered up the glued area with microfibre cloths to protect it from the sun and had a sit down with an iced coffee and a sammich.

Next Job…

If you read my previous post “Put Your Lights On Mate…” then you might have picked up on my request at the end for any recommendations for a UK supplier of good quality replacement LED bulbs. Well Peter Farnham posted in the comments section and recommended Classic Car LEDS Ltd ( https://www.classiccarleds.co.uk ). A couple of days later I dropped them an email with a few questions and Duncan replied back with some details. A few more exchanges of emails ended up with me ordering replacement LED bulbs for the new fog lights, indicator lights and stop/tail lights. This is not a sponsored post and I paid the required number of beer tokens for these.

Not much to say on changing the bulbs over… what was noticeable was though they did have a bit heft to them… they seem really really well made. No flexing, solid and just had that feel about them that made me go “Mmmm” while nodding slowly…. almost in a Joey Tribbiani moment.

I did try to do before and after photos to compare the light output…. even tried a short video with one side changed over and the other side on conventional filament bulbs… all failed…. not as easy as it looks in strong sunlight even though the caravan rear was in shade. However the photo above is one side converted over. This is showing the indicator, tail light and fog light lit. The indicators are really bright. Having the LEDS the same colour as the lens works well. The tail light is a strong red and bright while the fog light looks washed out and white… it’s down to the fact that it is so bright its over exposed…. the exposure is correct for the indicator and tail light but the fog light is amazingly bright.. and red.

On the VW Amarok I haven’t had any canbus warnings… I even plugged in my reader to check… all good and no strobing or hyper flash.

To say I’m chuffed with these LED bulbs is a bit of an understatement… if you suffer from rear light envy as you follow one of those gloriously illuminated trucks down the motorway, drop Duncan an email at sales@classiccarleds.co.uk and tell him I sent you. Sort out your rear lights and never again have someone with four megawatts of light bars and spots flashing you and shouting “Put Your Lights On Mate” as they simulate a starship going into warp drive passing you.

Another small job next…

I’d had this gadget for a while and I can’t remember where I got it from. I think it was from a caravan shop at a dealer near York that we visited a while ago.

Simply it’s a security head bolt with a hardened shroud that replaces the normal jockey wheel clamp handle. When it’s installed it is flush with the A frame cover and pretty difficult to get to. It comes with a short handle and socket that fits the security bolt head. I did try with a couple of sockets but the shroud makes it almost impossible to even knock a socket on with a hammer. So if anyone want’s to nick the caravan they now also have to contend with the hassle of getting round my jockey wheel clamp. As I always leave the caravan nose high in storage you can’t even pick it up and drop it on to a tow ball. Hey if it makes them try elsewhere… it works for me.

Thinking about the next step…

This is going to be a big one. I’ve been planning this for a few weeks now and it involves two or three drawings… some detailed planning and I’ve been checking equipment specs in detail. The last stage was to sit and stare at the space available in the caravan and work out Tetris style how it is all physically going to fit in and how much of the existing kit will be removed. More to come soon!

Back to the window…

OK I bet you have been wondering how I got on. Well after nearly five hours of curing time I disassembled my contraption holding the window open and it seems to have worked OK. I can see that it has bonded all along the bottom edge. I could have put a bit more glue in at one spot and needs a light clean up all along the bottom edge to remove what has oozed out. I’ll leave that for at least another 48 hours before attempting to gently sand it off.

All in all I’m pleased with the result and hope to see that it will stand up to the test of time.