Caravan Overhaul: Experiences with GRP Repairs and Jockey Wheel Replacement on a 1998 Caravan
Upgrading a Caravan's Jockey Wheel and Repairing the A-Frame Fairing
In a bid to improve the functionality and aesthetics of a 1998 Bailey caravan, a series of upgrades and repairs were undertaken. The caravan, purchased from Facebook Marketplace, required a new jockey wheel and a refurbished A-frame fairing.
Replacing the Jockey Wheel
The first step was to remove the old jockey wheel, a process that typically involves unfastening a pin or bolt that secures the wheel to its adjustable clamp or mounting bracket on the caravan. The existing wheel, being old-fashioned and narrow, made moving the caravan on softer ground challenging.
A new jockey wheel was chosen to address these issues. The Al-Ko heavy-duty caravan jockey wheel assembly, with a wider, all-plastic wheel, was selected, costing close to £70. This wheel would make the van easier to move on softer ground.
The new jockey wheel arrived disassembled, allowing for easy greasing and cleaning before installation. Once installed, it was evident that the old wheel's replacement had a definite buckle and a damaged replacement wheel costs £80.
Repairing the A-Frame Fairing
The A-frame fairing, a large piece of GRP that covers the chassis at the front, was in need of repair due to shallow surface cracks and light damage to the gelcoat top layer. GRP, or glass-reinforced plastic, is known for its toughness, lightweight nature, and ease of repair compared to ABS plastics, making it an ideal material for caravans, boats, and car manufacture.
To fix shallow surface cracks in GRP, it is necessary to grind along the line of the crack to create a V-shaped channel, then fill it with gel coat and allow it to cure. In this case, a Dremel with a round sandpaper bit was used to trace all of the cracks in the fairing. Strips of tape were placed as a guide for trimming the trailing edge of the fairing with a jigsaw.
The plywood plinth, made to support the leading edge of the shelf in the gas locker, reduced the space available for the A-frame fairing by 20mm. However, the alternative to tidying the A-frame fairing is leaving the van without it, which looks unsightly.
The A-frame fairing, now repaired, has improved the overall appearance of the caravan significantly. However, it remains scruffy compared to the rest of the vehicle, suggesting that further improvements may be necessary in the future.
After adding functionality and aesthetics to the caravan, consider enhancing the surrounding lifestyle by exploring nearby caravan sites for travel. While on the road, it's essential to maintain car-maintenance, including regular cleaning of the caravan. For those planning to upgrade their caravan, used caravans can be found on various platforms like Facebook Marketplace. If you've recently purchased a used caravan, cleaning the caravan, along with car-maintenance, can help maintain its value and longevity. For a more convenient travel experience, consider investing in a wide, sturdy jockey wheel, such as the Al-Ko heavy-duty one, to ease movement on challenging terrains. From time to time, caravan cleaning and car-maintenance should also include checking and maintaining the condition of your car.
