More like a mobile swimming pool.

[Johnenigma]

I have learned after we bought the motorhome that Buccaneer motorhomes were very expensive when new. I have seen 3 others on the road and 2 in Facebook. So not all that popular.
All seemed ok with it until looking at it September when getting ready to take for an MoT. Noticed that a roof panel at the rear appeared to have bowed slightly downwards with a very small stain on the vinyl on the join.
Post photos later.
Decided it was a project in the New Year.
Come January I decided to investigate the panel further, it seemed to be spongy and moved quite easily. I thought 'go for it' and ripped the vinyl from the panel and discovered absolutely rotten and waterlogged timber, the polystyrene was wet but not holding water.
The vinyl is wrapped all around the panel so water had got in but could not get out or dry out
Get my head round what I had found. Apart from this bowing there was nothing to give any indication of what lay in the roof. No damp smell at all.
Previously I had found water coming out by the side of the skylight and traced that to a loose connection and poor seal around the the Truma gas fire vent, Fixed that problem, looked at the skylight, although wood was wet, did manage to dry it out.
Thinks, this wet panel needs further investigation, take down the cupboards on the sides and the rear. Take more vinyl off roof panels, timber just as wet or rotten.
Have a look at the driver side rear wall, start pulling at the the vinyl wall covering, I think it was held in place by the cupboards because it came off very easily and revealed rotten and delaminated plywood.
The rear wall was as bad as the side wall. Hadn't started on the passenger side wall yet.
Well the plywood peels off like paper leaving all support battens soaking wet and rotten. The batten along the top of the wall is rotten because again this wrapped in vinyl and water has got in. This is where the title comes from, I have had water running down my arms removing ceiling battens.
Have a look at the passenger side wall, pull off a bit of vinyl to reveal the back corner plywood rotten and a lot of water stain with the top few inches rotten. Again the top of the wall batten is rotten.
The vinyl has played a major part in the destruction of the plywood walls but appears to have protected the floor, that seems solid with no discernable movement.
I have read the posts with regard to the repair of a motorhome and find them very interesting but I will be along with some questions of my own. I was going to do this project in a barn/workshop but that became unavailable.
I need my motorhome on the road for when we are allowed to start travelling again so taking advantage of lockdown to get on with the project outside my house, unfortunately out in the open.
With the removal of most of the ceiling and one sidewall, would I be better putting a temporary batten across walls?
The next job is to remove the toilet/shower cubicle to check on the state of the roof and wall as well as the horizontal wall battens.
Amongst the many tips that have been provided and I am thankful for are a reciprocating multitool (Lidl special, a couple of weeks ago) and the extending panel supports from Screwfix.
I will add some photos later (as soon as I can get them off my phone. Back up and sync aren't bringing them onto laptop).
Thankyou to every one who has posted on other restorations and takes the time to read this post.
Any hints, tips and suggestions truly welcome. My wife has already suggested 5 litres of petrol and a match.

 

[Tony50]

At the moment the roof panel comprises, in layers; roof, butyl tape, plywood, insulation and battens, aluminium, and plywood covered in foam backed vinyl.
Thanks for info about sawn timber.
What about painting 1st layer plywood in polyurethane paint?
The horizontal battens, ideally replaced in a continuous piece. It will have to be done in 2 pieces, can it be joined using a biscuit and Gorilla glue?
Thanks for your help and patience.

Good luck with your repair,
forget some of the not so funny remarks on here they often appear, but it's nice to see people like the Big1and others giving good advice.

 

[Johnenigma]

Good luck with your repair,
forget some of the not so funny remarks on here they often appear, but it's nice to see people like the Big1and others giving good advice.

I really like the funny remarks, it is a stressful time for me, so light hearted banter along with the good information is most welcome. Now have a deadline to get it finished for. Can anyone guess the date???? Hahaha

 

[Campervan_man]

If you find water ingress, fix the leak and replace any rotten battons with tanalised timber not untreated timber as if the van leaks again in the future the timber won't rot.

 

[mo@baggy]

I have learned after we bought the motorhome that Buccaneer motorhomes were very expensive when new. I have seen 3 others on the road and 2 in Facebook. So not all that popular.
All seemed ok with it until looking at it September when getting ready to take for an MoT. Noticed that a roof panel at the rear appeared to have bowed slightly downwards with a very small stain on the vinyl on the join.
Post photos later.
Decided it was a project in the New Year.
Come January I decided to investigate the panel further, it seemed to be spongy and moved quite easily. I thought 'go for it' and ripped the vinyl from the panel and discovered absolutely rotten and waterlogged timber, the polystyrene was wet but not holding water.
The vinyl is wrapped all around the panel so water had got in but could not get out or dry out
Get my head round what I had found. Apart from this bowing there was nothing to give any indication of what lay in the roof. No damp smell at all.
Previously I had found water coming out by the side of the skylight and traced that to a loose connection and poor seal around the the Truma gas fire vent, Fixed that problem, looked at the skylight, although wood was wet, did manage to dry it out.
Thinks, this wet panel needs further investigation, take down the cupboards on the sides and the rear. Take more vinyl off roof panels, timber just as wet or rotten.
Have a look at the driver side rear wall, start pulling at the the vinyl wall covering, I think it was held in place by the cupboards because it came off very easily and revealed rotten and delaminated plywood.
The rear wall was as bad as the side wall. Hadn't started on the passenger side wall yet.
Well the plywood peels off like paper leaving all support battens soaking wet and rotten. The batten along the top of the wall is rotten because again this wrapped in vinyl and water has got in. This is where the title comes from, I have had water running down my arms removing ceiling battens.
Have a look at the passenger side wall, pull off a bit of vinyl to reveal the back corner plywood rotten and a lot of water stain with the top few inches rotten. Again the top of the wall batten is rotten.
The vinyl has played a major part in the destruction of the plywood walls but appears to have protected the floor, that seems solid with no discernable movement.
I have read the posts with regard to the repair of a motorhome and find them very interesting but I will be along with some questions of my own. I was going to do this project in a barn/workshop but that became unavailable.
I need my motorhome on the road for when we are allowed to start travelling again so taking advantage of lockdown to get on with the project outside my house, unfortunately out in the open.
With the removal of most of the ceiling and one sidewall, would I be better putting a temporary batten across walls?
The next job is to remove the toilet/shower cubicle to check on the state of the roof and wall as well as the horizontal wall battens.
Amongst the many tips that have been provided and I am thankful for are a reciprocating multitool (Lidl special, a couple of weeks ago) and the extending panel supports from Screwfix.
I will add some photos later (as soon as I can get them off my phone. Back up and sync aren't bringing them onto laptop).
Thankyou to every one who has posted on other restorations and takes the time to read this post.
Any hints, tips and suggestions truly welcome. My wife has already suggested 5 litres of petrol and a match.

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[Johnenigma]

Well it has been a challenging few days since I first posted. As advised I stopped taking the motorhome apart and concentrating on a small piece at a time.

I removed a panel to find this panel from new. the hole to the right of the window is how I found it, there was no insulation fitted in the gap.

Driver's side rear, just ripped off the vinyl to discover rotten plywood. The fibreglass rear panel should be a attached to the horizontal wood battens. The battens and the rear window were fully floating, just attached at the top, bottom and sides.

More of the same wall.

One part of the roof. Taken half of it down, it is all like that and the side rails are just as rotten.

Another view of the roof. The panels are completely completely wrapped in foam backed vinyl. Damp or leaked water got inside and could not dry out.

Some of the rotten plywood has already been removed leaving the polystyrene insulation showing.

Driver's side wall, removing some of the rotten plywood it just peeled off.

Today, when doing some renovation I discovered this rail was not attached to the aluminium, water had separatated the glue between the batten and the aluminium. About 6 feet (2 metres) of wood is just a shell.

I believe that this pipe was the source of all the water damage in the roof. There should be a screwed collar on the pipe, I did tighten it up and reseal it about 18 months ago. it is the chimney for the Truma gas fire. I am thinking of doing away with the fire and fitting a Chinese diesel heater. This may have been leaking since the motorhome was new or fairly new in 2002.

The roof above the wardrobe, now held in place by the shower/toilet wall, which is still in place.

I have started to replace wood in the diver's rear panel and start repairs, The bottom rail along the floor was appeared to be OK, just reinforced with Ronseal wood hardener. The floor appears to be in good order, no soft spots on this side.

Thanks to all advice given and read on other posts on this forum. Much appreciated.

 

[pampam]

Wow you are lucky you have th talent and skills to do the repairs ,that could have been me cos i like buccaneers

 

[Phill D]

wow thats one shed load of work... keep at it

 

[Figaro]

Thats shocking
How long have you owned the van ?
I hope the renovation goes well for you

 

[Lenny HB]

I think you are well on your way to wining "rottenest Motorhome of the year decade" award.

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[rosalan]

A couple of thoughts.
Create, if it is not too late, a form of jig to hold the bodywork in true as you seem to have enough bodywork on a damp box to get out of true.
Get the whole job in a dry place where some heat could help dry out and keep you warm.
Marine chandlers are great when it comes to working with wood and water problems. They have great glues and advice on timbers and treatment as they are geared up to deal with wet wood.
I found a good one in Malden Essex when I was in a similar situation to you several years ago.
Good luck to you!

 

[tonyidle]

I believe that this pipe was the source of all the water damage in the roof. There should be a screwed collar on the pipe, I did tighten it up and reseal it about 18 months ago. it is the chimney for the Truma gas fire.

I bought an Adria caravan many years ago. It was the best van I owned as far as build quality was concerned. When it was imported to the UK a Truma heater was installed. The hole for the flue had been cut from the inside with a holesaw that created an uneven 'upstand' of aluminium on the roof. The flue was fitted correctly with the big rubber gasket outside and a backnut inside but the hole was left as cut and never cleaned up before the flue was installed. Realising his mistake the fitter filled the uneven gap under the rubber seal with silicone. I found this out when the van had stood over winter & the roof timbers and wardrobe were sodden. Not enough time to rot fortunately. I dried it out as best I could and traded it in for another van.

 

[Johnenigma]

Thats shocking
How long have you owned the van ?
I hope the renovation goes well for you

Owned van for 3 years. Thank you for your thoughts.

 

[Johnenigma]

I bought an Adria caravan many years ago. It was the best van I owned as far as build quality was concerned. When it was imported to the UK a Truma heater was installed. The hole for the flue had been cut from the inside with a holesaw that created an uneven 'upstand' of aluminium on the roof. The flue was fitted correctly with the big rubber gasket outside and a backnut inside but the hole was left as cut and never cleaned up before the flue was installed. Realising his mistake the fitter filled the uneven gap under the rubber seal with silicone. I found this out when the van had stood over winter & the roof timbers and wardrobe were sodden. Not enough time to rot fortunately. I dried it out as best I could and traded it in for another van.

The flue was cause of the water ingress on the motorhome. Yet to dismantle the flue from the aluminium. The wood just fell apart round the pipe. 2019 I did find water dripping out of a skylight and traced it back to the pipe. The nut was quite loose. Resealed the pipe, tightened the nut. Thought I had stopped the leak, dried the wood around the skylight and thought it was ok.

 

[Johnenigma]

A couple of thoughts.
Create, if it is not too late, a form of jig to hold the bodywork in true as you seem to have enough bodywork on a damp box to get out of true.
Get the whole job in a dry place where some heat could help dry out and keep you warm.
Marine chandlers are great when it comes to working with wood and water problems. They have great glues and advice on timbers and treatment as they are geared up to deal with wet wood.
I found a good one in Malden Essex when I was in a similar situation to you several years ago.
Good luck to you!

I did arrange for somewhere to dry store the motorhome over Christmas and then work on it from then on. I lost the dry storage, lockdown meant I couldn't go travelling around Milton Keynes looking for storage and working facilities under cover. Although at Christmas there was no end in sight for the easing of restrictions I needed to start work to get the van on the road. At the start didn't realise the task ahead. Doesn't a project always start like this? I am replacing the majority of the wood with new. I have left the floor to roof enclosure of bathroom/toilet in place as support. Fortunately the frame for the glassfibre end panel was wet but not damaged, so that is drying out. Will re-stick the frame and panel with glue and not as original, double sided tape. Got to get a move on now, get ready for April 12???

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[Johnenigma]

I think you are well on your way to wining "rottenest Motorhome of the year decade" award.

I have to agree with you!!!

 

[Johnenigma]

Wow you are lucky you have th talent and skills to do the repairs ,that could have been me cos i like buccaneers

I think more like stupidity and blind ambition! I have talked to 1 other Buccaneer owner a couple of years ago. There is 1 parked in a large car park near me, and talked to 2 owners on FB. Not seen another Commodore.

 

[Johnenigma]

I have been sourcing bits to begin to start the repair/rebuild. I have painted the bare aluminium with yellow household gloss paint as a barrier against the treated wood (which may be tanalised).

I have cut back the polystyrene to expose the wood piece at the bottom of the picture. All though the plywood was rotten, the batten was wet but there appears to be soft parts or rot, so presume it must be treated hardwood.
The floor appears to be in good order, didn't feel any soft spots and it had a good ring to it when tapped with a hammer.
On the safe side it has been treated to a bath of Ronseal wood hardener.

1 vertical and 1 horizontal batten installed. The white you can see is Gorilla glue PU adhesive. Bought that whilst waiting for a case of Puraflex 40 to arrive. I did support the side wall whilst pushing the horizontal batten against the wall. When the wall is completed I will be filling in the gaps in the polystyrene.
Any recommendations for a suitable adhesive or will a couple of dabs of PU40 be OK?
It is amazing how much the wall has stiffened up with just 1 batten in place.
When the wall are fully repaired and I come cover it, I am thinking of using 3.6mm ply, bought locally and then finishing it with household vinyl wallcovering. Getting hold of 3mm ply is very expensive. Transportation is the biggest cost.

 

[jongood]

That's the problem, it was too well built. The roof panels are wrapped in vinyl, the plywood walls are covered in vinyl. So water, damp or condensation has travelled behind the vinyl but could not dry out or escape.

I disagree, the problem is the structural wood, water will usually find a way in though heki s or windows and then it rots.

I have every sympathy with the Op.

 

[Podney]

Wow! What a task,I admire your skills and dogged determination! Good luck with it,at least now you can see light at the end of the Covid tunnel as well. We hope!

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[Lenny HB]

Pleased to see you supported the wall I was going to mention that but forgot. When I repaired a caravan many years ago the first bit I did, I didn't support ended up with a slightly curved wall.

I used the West System to glue the wall boards on, it's a two pack resin used for boat building. They make a range of resins now you need to make sure they won't attack the insulation.

https://www.westsystem.com/

 

[DJL220]

Reading your thread brings back the memories of my own MH Luckily you are linking in with some of the best people on this forum who’s advice will get you back on the road. As others have said find the source of the leak or leaks (in my case). Take each step at a time and ensure you support the structure well. Good luck with your repair

 

[Johnenigma]

Reading your thread brings back the memories of my own MH Luckily you are linking in with some of the best people on this forum who’s advice will get you back on the road. As others have said find the source of the leak or leaks (in my case). Take each step at a time and ensure you support the structure well. Good luck with your repair

Hi, I think your post was the first one I read and have re-read it a few times and everytime a bit more information sinks in.
As hard as it was, and soul destroying, you inspired me to start and then carry on.
You have had some knockbacks which you have bravely overcome and bounced back.
I like your feature wall and I am going to nick that idea, for when the time comes to decorate.
There have been some great ideas all round from other people on this forum, so much help. Thanks.
John

 

[Johnenigma]

There was a lighting circuit running right round the van. Because the roof was put on last, so the loom was dropped down through the insulation. There was a groove cut into the polystyrene to accommodate the wire. Ideally I would like to reinstate nearly like original. If I use polystyrene boards I know I can make or get a hot wire cutter to make a furrow for the wire, then put aluminium or Gaffa tape over the furrow. Any suggestions please?
An alternative will be Kingspan or similar, how would I go about putting a groove in it? I have never worked with or used it.
I rather like to bury the wire rather than using conduit.
Thanks for any input.
John

 

[Lenny HB]

Cut the channel and put plastic conduit in the channel, that's what the German manufacturers do if cables are needed in the roof.

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[Johnenigma]

Cut the channel and put plastic conduit in the channel, that's what the German manufacturers do if cables are needed in the roof.

Thanks for your answer. Any ideas on how to cut a tidy and neat channel in Kingspan or similar?

 

[Lenny HB]

Not really, hot wire cutter is the professional way, a shape knife or fine tooth saw will work but it don't 'arf blunt blades.

 

[Johnenigma]

Not really, hot wire cutter is the professional way, a shape knife or fine tooth saw will work but it don't 'arf blunt blades.

Just had a thought!!! My son was given the contents of the workshop when I ran a delivery company. Among the tools is tyre cutter. Hot sharp blade, ideal. Must get him to look it out. I know you didn't answer directly but sponsored the answer. Ta!

 

[Johnenigma]

I have been very busy with the swimming pool (motorhome). I have been digging out rotten or soft battens. Thank goodness for the oscillating plunge tool. The battens are glued on to the aluminium, so having to dig 2 metres of batten 50mm at a time. I have worn out a Lidl (Parkside) special in 5 weeks.

The yellow paint is gloss paint to separate the aluminium from the tanalised wood.
The yellow between the vertical blue batten and the polystyrene will be filled in with polystyrene that has been recycled.
Have started on the other side wall so that I can then start on the roof.

And finally, a rotten motorhome is the gift that keeps on giving.

This it bottom of the sidewall, I have only ripped the vinyl off. Not started demolishing, yet!!! When the time comes will have to find the source of the leak.

 

[Phill D]

You are a patient man

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[Al-Di]

I know your pain,