Tag Archives: Maintenance

Flushed With Success…

19 Friday May 2023

Posted by in Caravan Electrics, Maintenance, Technical, Thetford Toilet Repair

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We have just been for a short stay at Donkey Creek Farm in Freckleton, near Warton…. just up the road from Lytham…. that’s near Blackpool. OK you get the idea. We can’t recommend this site highly enough, in fact in a break of usualness I’m going to write a little review.

OK back to the main event. We pitched, set up shop and sat down to the usual post pitch brew…. “Ah I thought… I’ll just pop to the loo before sitting down”…. Pushed the blue button on the Thetford toilet and….. nothing, nada, not the slightest hint of a flush pump running. OK we had this once before and it was the fuse that had corroded, probably since it was located in one of the dumbest places possible…. but I won’t go into that. Nope not the fuse, terminal looked clean (probably because I’d given them a coat of protective terminal gel. Phooey it had to be the circuit board.

Using my trusty Swiss Army knife I peeled back the big Thetford sticker on top of the loo… and retrieved the circuit board. It wasn’t looking too clever.

The circuit board was connected to the loo’s wiring via an edge connector… OK for some applications. However on removing the edge connector the copper circuit board tracks had simply corroded away tot he point there was not much copper left on the circuit board.

The other issue was the edge connector was an IDC type (Insulation Displacement Contact) which basically means the wire is squeezed into a knife like ‘V’ in the terminal cutting into the insulation to make the contact.

The upshot of this was the circuit board had corroded, the contact surfaces where the connector contacted the circuit board pads had corroded and the cables had corrosion on their conductors. (in fact I had to cut the cables back by about 60mm to get to good un-corroded conductors)

Going Full MacGyver….

I did have a spare circuit board…. back in the Bat Cave at home….. wouldn’t do much good though as the edge connector was toast. With a Swiss Army penknife…. and my trusty tool bag… Time to do a “MacGyver” and get this thing flushing. I just happened to have a strip of 6 amp terminal block… well doesn’t everyone have a spare strip of terminal block? I cut the connector free from the wiring loom one lead at a time and transferred this across to the terminal block. Once all 6 were moved across it was a simple matter of finding Positive and Negative, jumping the Negative to the Negative side of the flush pump and providing a short fly lead that when simply touched onto the correct terminal on the terminal strip would run the pump.

The rest of the stay went well…. got some cycling in to Lytham for morning coffee’s… watched a few planes and watched the wildlife.

Back In The Bat Cave…

Back home it was time to fashion a contrivance that would not suffer the same fate…. heading into the Bat Cave I had an idea…

The terminal strip offered a way to still make the circuit board removable and replaceable but without the drawbacks of the edge connector.

I did try to source an edge connector but as per usual it was something that was a bit of a bugger to locate… unless I wanted 50 of the things shipped direct from China.

Here is what I cam up with. I’d directly solder short leads onto the circuit board and protect them with a coating of track varnish… something used to coat bare circuit board tracks on prototype boards to stop them from corroding. The short leads would be crimped with a boot lace ferrule after dipping the stripped ends of the cable in a protective anti-oxidising grease.

The finished article prior to coating the soldered terminals with a protective circuit board varnish, and finally assembled back into the circuit board holder…

Installation…

Installation was fairly quick and easy, the wires from he loom that I’d previously terminated on the terminal strip while away in the caravan were removed in turn, cut back to make sure there wasn’t any corrosion in the conductors, dipped in anti-oxidising grease before having a boot lace ferrule crimped on and being fastened into the new terminal strip.

The whole lot fitted neatly into the space below the circuit board and hopefully my little fix will keep the loo flushing successfully for the foreseeable future.

Another Little Job…

A while ago I swopped out the two LED spotlights above the bed (reading lights) for two that were a little less bright and that had USB sockets in their base. This left me with two ‘spare’ LED spotlights that matched those in the lounge area.

We have always thought that the location of these existing spots are great for reading, but not if you are having a meal. The lights provide a saintly halo behind your head but you plate of nom nom’s in front of you in shadow.

So I installed one of the lights right slap bang in the middle of the front overhead lockers points down at the table. So now when we are having a TV dinner with the lights low I can still see what I’m stabbing my fork into. It’s also handy of you want to do one of those artistic foodie shots…. here’s what we are having tonight.

That’s it for the moment…. unless you want to see a picture of a vary lazy cat who didn’t want to get up. Everything is better with a cat… especially if it is Henry.

Lighting Up The Scene…

25 Saturday Mar 2023

Posted by in Accessories, Car Trailer, Caravan Electrics, Caravan Road Lights, Electrical, Gadgets, Maintenance, Modifications, Projects, Technical, tow vehicle, Towing, Vehicle Wiring Projects

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A while ago I upgraded the lights on our caravan by changing the functions round and added two new LED reversing lights which I can’t understand why I hadn’t done this years ago. In daylight they are bright… and at night they are really bright… retina burning bright according to reports. Reversing into a dark pitch is a lot easier and safety wise having an additional set of tail and brake lights with two large bright rear fog lights instead of the single factory 21 watt light mounted almost as low as you can get on the rear of the caravan is a vast improvement in my mind. You can read about my changes here… “Put Yer Lights On Mate…“

Following that article I had lots of people contact me letting me know they liked what I had done and considering upgrading themselves. Not a clue if anyone did, but that’s how these things go. I did have another email from a gentleman which was a bit different. Now I’ve edited it a bit as it was originally two emails and included a company name and some specific details which I’m sure they would not wish me to publish to the world…. here’s the gist of it though:

“Hi Simon, been reading your blog for a while and I read your post about upgrading your caravan lights. I was wondering if you might be able to help with something we would like to do with our trailers or could put us in touch with someone who can? We have around eight trailers that are used on various locations separately or as a group and are towed by a variety of vehicles, mostly our own but occasionally by contractors. Most of our trailers have additional side lighting powered off the trailers own batteries which are charged from the vehicle or while on site from generators. A lot of our set up and tear down is done at night and we have had issues at dark locations where the vehicles reversing lights don’t really help. Is there any way we could get the side work lighting to come on when the vehicle reverses but could be controlled from the vehicle without any additional switches or alterations to the vehicles but could be turned on and off as reversing on a public road with them on might not be legal”

From an exchange of emails, I do know what the company does and some of the sorts of places it works. They don’t always have access to mains power when setting up or tearing down and would like something that can easily be installed in a trailer without too much alteration to the electrical services. Nothing could be installed in any of the tow vehicles as the vehicles were not always their own and I first suggested a cheap(ish) remote switch that could be used by the driver to turn them on and off as required. I was told this was not an option as the remote switches would likely get lost/damaged or need batteries or be with the wrong crew, some sites they could not use any radio equipment.

Time to put my thinking cat on…

Polo…. always a great thinking cat, sadly no longer with us.

I had a bit of an idea forming. Something I’d seen on a Class A American RV (Prevost I think) was a set of spotlights set in the side panel of the RV pointing backwards and located near the front wheel. These lit up down the side of the RV and the ground to the side when reversing…. I’d thought about adding a couple of simple cheap LED lights to the underside of the caravan between the wheel and front of the caravan angled outwards by about 60 degrees mounted under the floor… so when I reversed they lit up the caravan wheel and the ground it was going over so I could see it clearly at night in my mirrors. I had pondered how to switch this on and off using the Amarok but not add any more wiring between the caravan and vehicle. So I’d already come up with a solution.

Here is what I came up with…

It’s a simple two relay set up. The two triggers for this to work are the vehicle reversing lights and the rear fog lights. The top relay in the box is activated by the vehicle being in reverse with the reversing lights on. The lower relay is activated by turning the vehicles rear fog lights on. Only when these two conditions are met, is there a circuit across the two relays switches made thus activating the work lights on the trailer.

Quite simply when reversing to turn on the work light simply turn on the rear fog lights and the work lights will come on.

Cables 1, 2 & 3 connect to the road lights. Cables 4 & 5 are for the switched load. The cost was around £15 for the components for each unit and that included Bosch relays & sockets, the die-cast box and fuse holder. I guess putting it in a plastic case and using cheaper eBay sourced relays could halve that cost.

I did also think that as an upgrade or option the relay operated by the reversing lights could be a timer relay. Set it to say 15 seconds, then when reversing you turn on the work lights and they will remain on of 15 seconds after reversing as long as the rear fog lights are on. This would give you time to reverse, pull forward and reverse again. Each time you select reverse the timer would reset and as soon as you disengaged reverse the timer would start its countdown again.

High level work lights could be a boon to reversing into dark pitches or storage sites. Image take from the internet, copyright not mine.

It was as simple as I could get it using existing signals from the vehicle that already pass through to the trailer. I guess it could be used to turn anything on using any combination of lights operating from the vehicle.

The wiring between the road lights and work lights is kept separate as I wasn’t 100% sure how the trailers power system worked and how it was connected to the road lights (if at all) The two relays were installed in a die cast box with a grommet for the 5 cables. All the trailers were fitted with one of these and apparently they have all been working fine for several months.

Why did I opt for reversing lights and fog lights?

I wanted something that would not be used generally through the day so reversing on a public road during daylight or even at night the work lights would not illuminate. Running during the day with lights on and your fog lights will not operate the working lights… and if you are running in weather that requires headlights and rear fog light… then I guess having the working lights come on while you reverse in those inclement weather conditions just makes you more visible to everyone around. So apart from that I don’t think that you will cause a danger on the road with this set-up.

So…. I think I might just have to install one of these on my caravan…. just in case!

Low level scene lights down the side of the trailer can be just as effective as high level work lights. Image taken from the internet, copyright not mine.

Its a fairly simple DIY job to build a box and install it without too much messing about with the original wiring. Now someone asked me about getting the orange side marker lights to flash in time with the indicators…. and remain as side markers when the indicators weren’t being used. Is this something I need to put my thinking cat on for? Let me know in the comments.

Finishing Off A Few Jobs…

09 Thursday Sep 2021

Posted by in Accessories, Caravan Electrics, Caravan Restoration, Caravan Servicing, Caravan Window Repair, Gadgets, General, Modifications, Technical

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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.

“Put your lights on mate…..”

28 Saturday Aug 2021

Posted by in Accessories, Amarok, Caravan Electrics, Caravan Road Lights, General, Maintenance, Modifications, Projects, Technical

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How many of you have driven behind a vehicle in less than ideal conditions… going dark, raining or foggy… and uttered those immortal words “Put you lights on mate” in the vein hope it will do some good only to approach a bit closer to find that the lights are on and are less effective as a couple of Ikea tea lights in jam jars. That is the feeling I get with a lot of caravans. In my opinion a lot for rear lights are less than ideal. In this day and age some of the drivers out there need all the help they can get as they even struggle to notice a big white box in front of them in bright sunshine let alone in inclement weather or in the dark.

Our caravan like a lot of other Swift caravans looks great from the rear with nice big lights and reflectors. Reflectors are good if the following driver has turned his headlights on and not been too busy texting and simply relying on the DRL’s to light the way. The big reversing lights will surly let the driver and anyone else behind know you are reversing… but about as useless as the aforementioned Ikea tea light in a jam jar when reversing at an angle into a pitch at night. The rear fog light however deserves a special mention… the single rear fog light…. can you see it… the tiny Lego brick sized rear fog light… the red thing in the middle down low… difficult to spot on a stationary caravan in daylight let alone from a distance on a road in fog. Mind you when that bit of wire in the bulb warms up it will blind you… honestly it will…. eventually… when you get so close because you didn’t see it from ten metres away.

Its time for a change. An upgrade if you will… to allow me to shine a beacon of light towards all that follow. But… and here’s a the big thing… I have to keep it looking nice. Everyone likes a nice rear don’t they.

OK, I searched for all the replacement options. Swift don’t make it easy. The two panels that the lights are mounted in don’t come out, well not easily and I was cautioned about even attempting to remove them. Changing to smart round LED lights was out. Then it struck me… the reversing lights could become fog lights and I would install new reversing lights. I’d towed a trailer a while ago that had football stadium sized reversing lights and wow what a difference it made. One of the first things I did with the Amarok when we got it was to install LED work lights under the rear bumper as reversing lights and that was a huge improvement so I ordered another set from the same company as I’d fitted to the Amarok.

A bit more searching I found the exact lenses for the existing lights in red to turn the reversing lights into fog lights.. it was actually cheaper to order a pair of complete lights than it was to order two replacement red lenses… I’ll never work that one out.

Ok how was I going to wire this lot up. I made a couple of brackets that fitted under the caravan allowing me to mount the reversing lights up close just inboard of the rear steady jacks. This would offer a modicum of protection from road debris thrown up by the tyres. These could be wired to run off the old fog light which would now become a junction box and the reverse lights would become the fog lights, so simply switching the reverse light and fog light cables over at the road light fuse box in the front of the caravan would have everything working correctly.

I also angled the reversing lights out slightly. I wanted the centre of their light pool to be along an extended side line of the caravan so that looking through my mirrors down each side of the caravan would be the centre of the lit area. This hopefully would provide the best angle of illumination when reversing and performing a reversing turn onto a pitch.

“Hang on lads… I’ve got an idea”

Cue the music… no, no doors were blown off during this mod. Right what if the new rear fog lights could be my brake lights when they weren’t being used as fog lights?

A simple diode blocking bridge using two diodes could do this quite easily. Routing through my electronics spares I found a bag of 10 Amp diodes which would easily cope with the task.

For a quick solution I used two strips of terminal block and built a quick blocking bridge. What happens now is applying the brakes powers up the brake light circuit and the fog lights. The diode in the fog light circuit stops me back feeding current to the tow vehicle fog light circuit.

Turning on the fog lights powers up the fog lights and the diode in the bridge stops it powering the brake lights in either the caravan or back feeding to the tow vehicle. Really simple and when testing I didn’t have any canbus or other errors thrown up by the VW Amarok’s management system. The existing (and original) brake and tail lights work as normal.

I’ll have a look at coming up with a better solution than using two lengths of terminal strip and probably build something in a small electrical project box so it can be mounted securely.

As far as I can tell the changes I’ve made all fall in line with the lighting regs for trailers. While I’m 99% sure, there is always the possibility that I could be corrected and shown the error of my ways and point out I have missed something in my reading of the regs. I’ll let you know.

The next thing…

I’m trying to find some good quality bright LED replacement bulbs for all the rear road lights. I have some, but I suspect they are not correctly marked. If anyone has any recommendations for replacement 25W and 5/25W bulbs that they deem are good options to look at, especially if they are correctly marked, please let me know in the comments. If you are a company that sells LED replacement bulbs and think they are the good enough to pass the Caravan Chronicles testing department (we don’t actually have a testing department… its just me) then challenge me to break them!

Safe travels everyone… and “PUT YOUR LIGHTS ON MATE”

Well that took some cleaning…

21 Saturday Aug 2021

Posted by in Amarok, Cleaning, General, Maintenance, Tips

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Our first visit to the caravan storage site in quite a while to check on the caravan was undertaken with some apprehension. It had been over twelve months since we had checked on it and we expected that we were going to be in for a shock.

The caravan was very dirty on the outside but it was the inside we most feared. Opening the door….. it didn’t smell musty…. we couldn’t see any mould… and nothing felt damp. In fact inside was in really good shape. Leaving all the cupboard doors open, the bed partly raised and the roof vents cracked open a touch seemed to have worked. OK, now a list of jobs that needed doing. The leisure battery is now 10 years old and given us good service. It needs replacing… more on that later. The tyres also need replacing and the outside needs a good clean and polish.

I removed the leisure battery which was showing as dead… less then 10 volts, put it in the back of the Amarok and we headed back home to come up with a plan of action. A couple of days later we returned with cleaning supplies…

We hitched up the caravan and pulled it forward out of it’s parking spot and set to work. Over the years I’ve tried all the different products for washing the caravan (and cars) ranging from mid priced to the “how bloody much” brands, but in all honesty I have found Morrisons own Wash and Wax Shampoo (It’s bright green) to be really good and it has given me really good results on our 15 year old Freelander, the Amarok and the caravan. A long handled brush for the sides and some small detail brushes for the awning rails and tight places made easy work of the sides. It was all hosed down using one of those pump up pressure washer thingy’s

To rinse I used Car Plan’s Demon Shine (the pink stuff…. also stocked in Morrisons) diluted down in the yellow pump up spray do-hicky. Which works quite effectively. The two products – Morrisons Wash and Wax shampoo and the Demon Shine seem to work together really well and I certainly found that using the two as a shampoo and then as a diluted rinse leave a good water shedding layer on the Amarok that lasts quite a while.

One thing we don’t have at our storage compound is running water. So I have three 25 litre containers that I fill up at home and throw into the back of the Amarok. To save lifting them up to fill buckets…. I fitted a hosepipe connector to one of the lids and all I need to do now is tip the container and open the tap. As there is no venting the sides collapsed inwards a little so tipping it back onto its side from time to time to let air back in means that when the tap is shut nothing can slosh out a vent while travelling.

On this trip we only cleaned and polished the sides… the roof would have to wait for a return visit. Putting the caravan back in it’s spot lead to the next task…. jack it up and remove the wheels. The caravan was fitted with Hankook 185×80 R14 and inspecting them closely revealed no cracks, bulges or damage of any kind. These tyres were now 10 years old it was defiantly time to replace them. We got 8 years use and just over a year standing out of them and I consider that a win. Realistically they should have been replaced at 5 years…. 7 max at a push, so getting 8 out of them with close inspections each trip I’ll consider we got our money’s worth out of them. After much searching on line and checking out the discount with National Tyre via the Caravan and Motorhome Club I called in to my local National Tyre could fit replacements and beat the price even that C & M Club discount gave us with National Tyres on line. As the Hankook’s had given us really good service and long life I replaced them with another set of Hankook’s. National Tyres also fitted new valve stems, valves and balanced the wheels. I know there is a lot of debate about balancing caravan wheels…. well the engineering bit of my brain thinks that anything rotating should be in balance, so I’m going to balance my wheels. We picked the newly re-shod wheels up the following day and returned to the compound to fit them. As it was raining, cleaning the roof was put off until we had better weather.

OK…. I know… you are all saying “Why did he clean the sides before the roof….. that’s bass acwards” OK here is my thinking…. the roof is going to take a few hours to do properly and when you have done that you then have no choice but to do the sides straight away as they are going to be really filthy with all the run off. It’s going to be a really long day to do everything. By doing the sides first, we could get a good layer of wax protection on them and as said earlier, the combination of products give a really good beading coat. So when it comes to washing the roof a simple rinse down would restore the sides back to their pristine finish we had a few days earlier.

As I worked round the roof scrubbing and rinsing, Sue followed me with a squirt bottle and microfibre cloths… using the Car Plan Demon Shine neat finished off the sides and gave another layer of buffed waxy finish.

A few other jobs were completed too. All the window and door rubbers were given a good coating of Sonax Silicon… this stops the windows sticking to the rubber and keeps the rubber seals soft and supple. Some of the aluminium awning rail needed cleaning. Rather than use a metal polish (Solvol-Autosol is my normal preference as a metal polish) I used a simple rubbing compound so as not to polish the aluminium too much but brighten it’s brushed finish. And finally waterproof silicone grease for the moving and interlocking parts of the 13 pin plug.

What next?…

I mentioned earlier that our leisure battery had died… well after some tender loving care in the workshop… It’s alive! Well it’s OK for light duty. So the next project is to go lithium. I have planned out a course of action and the first step is to install on the Amarok a 50 Amp feed to the rear of the vehicle and terminate in an Anderson connector. This will allow me to use the full capability of the Amarok’s large alternator to charge Lithium batteries in the caravan via a dedicated DC to DC charger. Next stage will be installing a solar regulator and panels followed up by an inverter and changing the on board charger for a dedicated lithium charger. I also want to remove the inbuilt charger to save weight and make room as I won’t be installing any lithium batteries in the existing battery box.

I’m still in the process of doing my due diligence on equipment for this so watch this space. I’ll go through my thought processes in a later post.

The other change is going to be the rear lights on the caravan. The reversing lights are not very useful when reversing on to a pitch in the dark so I’m going to install two LED wide beam lights just out board of the rear steadies. That leaves me with the existing reversing lights. A quick search on the internet led me to replacement Hella lenses for the existing reversing lights that would allow me to convert them into fog lights with a simple lens change and a wiring change at the fuse block. Swop the reversing light cable with the fog light cable and use the old fog light as a connection point for the new reversing lights… after removing the bulb of course!

An Easy Fix…

23 Thursday May 2019

Posted by in Caravan Servicing, General, Maintenance, Projects

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You know how sometimes those little jobs come along that you put off as you think that it’s going to be a bit of a pain to do…. well this was one of them.

IMG_1652

On all three of the front windows the plastic insert trim for the rubber window surround was slowly pulling out of the corners. The worst was the front lower corners on the big central window. I’d ordered 15 metres of replacement from Leisureshopdirect.com (the part I ordered can be found here) for about 99p per metre. It was one of those jobs I’d been putting off for a while as I thought it was going to be a bit of a nightmare to do.

However on a recent jolly to Riverside Touring Park at Betws-y-Coed, one afternoon sat looking at it I decided I’d sat looking at it far too long and that it just had to be attacked head on.

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Tackling it from outside, releasing the window hardware on one side – marking where the screw holes were on the rubber in pencil first, was easy enough. Two cross head screws held in each window latch and window strut to the frame of the caravan. The join in the old strip was in the centre at the top and getting a small flat blade screwdriver under the edge was easy and the the strip simply pulled out across the top and down one side.

I started by checking the width. When you order there are two widths available and two colour options. I’d previously checked the existing strip and measured it to be about 23mm wide. On the web site it was listed as 23 mm or 25mm and available in grey air white.The replacement was however around 50% thicker making it a lot stiffer to insert.

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However it soon worked out that this additional thickness was to my advantage. I could now push the strip into the recess on the caravan side and simply run a small cross head screwdriver round the outer ‘flange’ (I had to get “flange” in there somewhere… silent nod in the direction of Miranda Hart) and flip it over the edge of the strip. The first corner was a bit tricky but my technique was improving all the time.

Once I’d completed the first section from the top down to the middle of the bottom of the frame, I re-attached the window hardware and removed the opposite side…

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This was all going terribly well! It didn’t take too long to remove the hardware from the other side of the window, pull out the old strip and continue around the frame fitting the new strip in.

I wasn’t sure what caused the original material to pull out of the corners but I guessed there might have been some stretching when it was originally installed and maybe  repeated heating and cooling over the last 8 years caused it to return to it’s original dimensions. With the new strip, I did try to ensure I’d not pulled it tight and used the handle of a large screwdriver to try and massage the strip into the corners as much as possible.

All that remained was to re-install the window hardware on this side and check for fit and finish. Everything seemed OK and Granville was summoned with his cloth…

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A light squirt of silicone designed for rubber window seals and a quick polish with a microfibre cloth finished the job off nicely.

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All totalled the main centre window took about 30 minutes to complete start to finish.  Next trip out up to Barnard Castle in a couple of weeks time…. I’ll get the other two smaller windows done.

Finally, before anyone asks, yes I did choose to do this on the warmest day in North Wales so far this year!

Testing the Bosch Fontus…

24 Wednesday Apr 2019

Posted by in Accessories, Cleaning, Maintenance, Reviews

≈ 2 Comments

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As many of you know I don’t really do reviews… I occasionally buy things and put my thoughts on the product in a post. Companies do contact me and ask if I’d review their ‘Do-Hicky Mark 4’ on the blog and most of the time I decline. Why? Well a lot of them stipulate that they want to see anything I write before it’s posted, we’ll sorry no. If I think it’s crap, I want to be able to say so. There are a couple of companies that I deal with that say “We are thinking of importing/manufacturing/marketing the ‘Functionvardle Mark 9’ we would like to send one for your feedback and not for reviewing on your blog.” They do get an honest feedback and I never mention the company or the product in my blog…. Even if the “Functionvardle Mark 9” makes it to market.

This was slightly different. The PR department simply said “We’d like to send you a Bosch Fontus for review” No requests for editorial control, previews before publishing, promises of ‘it’s yours to keep’ if we like the review. What made me say “Yes” to this particular  request?

Well, for a while I’d been procrastinating on coming up with a contrivance of my own that did a similar job. I’d bought one of those bright yellow overgrown pump up spray things when they were on offer for rinsing down the caravan after cleaning… we have no water or electricity at the storage site we use. I’d already got three of those 25 litre water containers that I’d throw in the trailer along with the buckets, brushes, ladders… everything for a cleaning mission down at the caravan storage yard… and I thought it wasn’t beyond the realms of reality (and my awesomeness) to throw a 12 volt pump…. some hose…. a couple of hose connectors….  length of cable…. fuse & fuse holder……  suction pipe… board or box to hold it all…      you see where this is going? By the time I’d assembled all the bits found I’d got half of them wrong and moved the goal posts half a dozen times.  Apathy set in and I resigned myself to keep pumping the big yellow spray thing. The nice Lady from Bosch PR hit me in a weak moment and I thought “Hmmmmm.”

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OK why “Fontus” and not “Rechargeable Battery Powered Portable Water Reservoir and Spray“? Fontus, I had to Google it – In ancient Roman religion, Fontus or Fons (plural Fontes, “Font” or “Source”) was a god of wells and springs. So that answers that question. Now you know why I don’t work in product marketing! The box arrived and I was surprised at the heft of the box. The actual unit itself weighs in at just under 10 Kgs…. and has a water reservoir capacity of 15 litres.

So what is it… well basically it’s a Rechargeable Battery Powered Portable Water Reservoir and Spray Unit. You fill it up with water, insert the rechargeable battery, connect the included hose and spray head, push the ON button and squeeze the trigger. Is it a jet wash? No, it runs at a max of around 1.5 MPa that’s 15 Bar or 217 PSI to you or me or if you are really old 14.8 Atmospheres. So it’s not a jet washer.

Now here is the thing that has me fascinated. On the top there is a three position power switch. While testing (read playing around) I could tell it changed the power… but also it seemed to change the amount of water without affecting the spray pattern or distance it should spray the jet of water I could do the same width ‘fan’ of water on each of the three power settings but with three volumes of water. (OK I know the physics behind it… no need to comment.)

When washing the car when it comes to rinsing off I normally have my hosepipe rose set on ‘rain’ so its a constant rain shower and proceed to go round the whole vehicle rinsing off the shampoo (yes I shampoo my vehicles… get over it) Now with the Fontus I used the horizontal fan setting not he trigger and could literal have a line of water that I just moved down the body panel pushing the shampoo suds down as it went. I was amazed I could do the whole of the VW Amarok.. Which isn’t small… on less than 15 litres on the lowest power setting. That is some serious water saving there.

The battery duration is unknown at the moment. It comes complete with a 18 volt 2.5 Ah battery and charger, that are as far as I know the same Bosch fitting as used on many of their power tools. SO if you already have Bosch power tools it’s Billy Bonus time… another charger and battery for your tools and spare batteries for your Fontus. (Curse my early lifestyle choices for going with Makita and DeWalt.) I believe there are also 4.0Ah and 6.0Ah batteries available in the range.

Toy or Tool?

After first thinking what a great idea…. I had a look at the price… an eye watering mahhosive amount… list price. However as everyone knows “Google is you friend” a quick Google later and John Lewis & Partners have it down to £209* (*at the time of writing) Now that is not a small amount so the question is… expensive toy or tool? Well, After my initial “testing [read playing about again] I’d been jet washing in the front garden over Easter… around five hours worth of jet washing in fact and the front door and windows were to say the least showing the dried on signs of mud splattering. Now Sue is understanding, but waiting for the window cleaner to deal with it was not an excuse I was going to get away with! Not wanting to drag the hosepipe round to the front of the house again, I had a “Ha.. I have just the tool for that” moment and having already recharged the battery and topped off the water tank I wheeled the Bosch Fontus out of the garage and round to the front of the house. A quick light spray to wet each window and door, wipe down with a soapy sponge and rinse off with the Fontus. Done in ten minutes. It’s also completed several other little tasks around the home now too.

Would I take it with me on a caravan trip?…. If we were taking the bikes, yes. I have used a dog wash station in the past (I know I wasn’t supposed to) and as long as I don’t use a chemical on the bikes, just rely on pure water and the included brush I should be OK washing the bikes on the grass. I wouldn’t use the brush on a vehicle’s bodywork (but I’m a bit OCD about things like that) nor would I wash the vehicle or caravan for that matter, on a pitch.

 A few Q and A’s…

  • Can it be carried full of water? – Yep, I also tried it on its back, the filler cap seems to have an air admittance valve that stops water from leaking out. I wouldn’t do it for long periods though on it’s back… just the ten minute trip to the caravan storage yard. Upright shouldn’t be a problem I would have thought.
  • Can you spray anything else? – Nope… fresh water only.
  • Can you see how much water is in the tank? – Yes the tank has a site gauge in each side.
  • Can you store it full of water? – I did for  few days, however it cautions you not to do so in the instructions.
  • How big is the filler cap?–  It’s about the same size as an Aquarol filler cap and has a removable mesh filter trap… I could get a Hoselock fitting on the end of my hosepipe to fit through the opening and wedge in the filter when filling it. It’s also easy to poor water in from a container.
  • How heavy is it full? – 9.8 Kgs empty and 24.8 Kg’s full… so about two bags of sugar heavier than your airline baggage allowance.
  • How long does the battery last? – well I certainly got through 30 litres of water (2 tanks) on the low power setting (which was all I needed for rinsing off) and looking at the battery indicator maybe I could have made inroads to a third tank. I don’t know if the battery indicator is liner or not.
  • How long does it take the battery to recharge? – From battery empty indicator to full with the supplied AL1830 CV charger 60 minutes… or about 1 cup of tea, two digestives and a quick catchup with your neighbour.
  • Is it easy to move? – When full it trundles around just like one of the wheeled over head locker type pieces of luggage. If you can drive one of those… you can handle this.
  • Will 15 litres be enough to rinse a caravan? – Yes I could do it with 15 litres. But it’s easy just to have a container with a bit more water.
  • What fittings connect the hose, can I use a garden hose? – The fittings are a twist lock type.. not seen them before but I did like the fit and function of them. They seem quite suitable for the task. Why would you want to use a garden hose… just wheel it to where you need it.
  • What else can it be used for? – Washing off salt water from wet suits, boat trailer, outboard engines, muddy dogs, muddy bikes, wellies, washing windows, washing the beach off anything….  making sure your BBQ is properly extinguished (as I write this I keep getting the smell of burning moorland wafting in through the open windows into the office).

Anything Else?

Only two things… do they make a 12 volt ‘in car’ charger for that battery? That would be really cool and…. nope I got nothing else. That will be one thing then.

Final thoughts…

If I already had a couple of Bosh power tools that used the same battery pattern and was thinking about an additional battery and charger… then the price makes it a good deal. An extra tool that gives you an extra battery and charger into your Bosch ensemble of kit.

The hose is not as pliable as I’d have personally liked, but then again looking at it it’s not going to get damaged easily.

It is a bit of a ‘luxury’ bit of kit… but then again once you start using it… I’ll stop there, Sue might be reading this.

Do I want one? Well  I don’t really want to give this one back.

Overland Vehicle Electrics and Other Stuff…

17 Wednesday Apr 2019

Posted by in Caravan Electrics, Electrical, Help Guides, Maintenance, Modifications, Uncategorized

≈ 16 Comments

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I seem to have had an increase over the last few weeks of emails from people involved in building, modifying or upgrading Overland Expedition type vehicles. I think some of my posts must have been quoted or referenced in related forums. A lot of questions are related to roughly the same group of topics so I thought I’d produce three drawings to help answer the bulk of the questions. If you read down the comments on some posts I have answered a lot of specifics that might help.  I’ve merged a lot of the questions into a paraphrased ones…

Question 1

“How can I get my LED light bar and spotlights to come on when I use my main beam switch but I want to disable them when on the highway?”

Auto Switch Driving Lights

Link to A3 PDF – Auto Switch Driving Lights

The questions were from a number of 4 x 4 Off Road enthusiasts and Overland vehicle people. Simplest way I could come up with was using a couple of diodes (details on the drawing) Three switches… one for LED Light Bar, One for Driving Lights and one that allows you to sync the LED Light Bar and Driving Lights to the operation of the main beam in the vehicle. Flash the main beam and with the Sink Switch ON… all the lights will flash. Note… this may be illegal in some countries, so having the option to turn off the facility when on the roads ‘should’ keep you within the law…. don’t quote me on it!!!

Question 2

“Whats the best layout for connecting a solar controller / inverter / isolation switch to my battery bank?”

Overlander Wiring Diagram - 01

Link to A3 PDF – Overlander Wiring Diagram – 01

The best schematic I could come up with that is flexible for most situations. I’ve put a few notes on the drawing. The various components I’ve drawn generically…. all can be found at your preferred supplier.

Question 3

“What’s the basic layout of the vehicle fridge and leisure battery charing circuit?

Basic 13 Pin Power Loom 1

Link to A3 PDF – Basic 13 Pin Power Loom 1

This I think has come from a few on-line discussions relating to poor performance of the fridge and leisure battery charing in older 4 x 4 vehicles. I was receiving for a while a number of questions related to upgrading older installations. I also receive a number of emails asking how to add the facility of fridge and leisure battery charging to older vehicles and upgrade the 7 pin tow socket or old military lights socket.

You can download the PDF’s and are free to use for personal use. If you post them on other forums I’d appreciate a link back to this page and/or an acknowledgement.

I’d appreciate any feed back in the comments below.

A Quick Fault Finding Tip…

12 Friday Oct 2018

Posted by in Caravan Electrical Fault Finding, Caravan Electrics, Caravan Fault Finding, Caravan Servicing, Electrical, Technical, Tips

≈ 18 Comments

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Sometimes things you take for granted and have in your toolbox of fault-finding tricks are a dark art to others.

I was talking someone through a bit of fault-finding on their vehicle and asked if they had measured the current in the circuit. “No” came back the answer. I asked what type of fuse and rating it was and asked the person to just put their voltmeter across the fuse and tell me the voltage across the fuse. “Ah… that’s about 3.2 amps then” I said.

“How do you know that?”

Simple really – all fuses have a resistance and if you know that you can work out the current from the voltage drop. Even simpler really – there are tables for various fuses that have it all worked out for you. I have a selection collected over the years stuffed into the lid of my tool box, along with a lot of other junk paperwork!

I created a volt drop table based on PEC (Pacific Engineering Corporation) fuses that are supplied as OEM fuses in most Japanese, Korean and European vehicles however it is pretty accurate for almost all other makes of the same type of fuse. I printed mine out, laminated them and added them to the collection in the top of my toolbox.

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It’s quite easy to use. Just set your multimeter to read DC mV and read the voltage displayed. Now select the fuse type, in this case an ATO fuse – the most common used in vehicles, caravans and motorhomes and from the chart look down the left column until you see the voltage measurement that matches the one on your multimeter… lets say 0.011 volts (11mV)

The fuse is a red 10 Amp fuse so follow the 0.011 volt line across until you get to the 10 Amp fuse column and read the current figure… in this case 1.3547 or 1.3 Amps. It’s as easy as that, no need to break the circuit to put your multimeter in as an Ammeter.

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I have a couple of these cheap handy plug-in ammeter’s…  although they do have limitations and only work up to 20 Amps.

Although the table is based on PEC ATO/ATC and MINI fuses (download info below) it is pretty close with most manufacturers fuses and as a general reference for fault-finding will be good enough to 0.1 amp.

If you need to know the actual current through a circuit, you need to use an ammeter and not rely on tables but for general work they are close enough.

These tables also come in handy if you are trying to find out why a battery is draining. Without turning anything on it is easy to run through a fusebox checking to see if any circuits have a current drain on them without having to constantly pull fuses and insert an ammeter, which sometimes can upset or reset the circuit you are working on.

One thing to remember with this test if you’re tracing a fault, is you are only measuring the volt drop across the fuse to determine current. You really need to know how much current you should be drawing. For example, If I was testing the 12 volt fridge circuit fuse and I only got a voltage drop across the fuse that calculates to 6 Amps then I’d know there was an issue somewhere along the circuit as I’d be expecting around 10 Amps or more.

A word from our Safety Officer…

"Oscar" our senior safety cat.

Oscar would like to remind you that working on a live circuit has risks and never attempt to undertake volt drop measurements on mains circuits. Most cheap multimeters do not have the internal protection or fused test leads. Be safe. Be like Oscar.

You can down load the table in PDF format (4 pages) and either print them out or save them to your device from the following link: Fuse Voltage Drop Table

Unfortunately due to a lot of my drawings and text being used elsewhere without credit back to CaravanChronicles.com  I’ve had to start putting watermarks on a lot of things. I hope this doesn’t make the table too difficult to read.

P.S. Someone told me that everything on the internet can be improved by cats and my “likes” would go through the roof!