Tag Archives: Things that go wrong

Buns on the Bridge

With the Covid Germ still out there still and it stifling our travel plans, I thought it would be a good time to revisit our month in  Europe in a  Motorhome  following friends Gary and Dianne a few years ago…  about 15 odd posts!

Enjoy

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The temperature had dropped from the 30’s down to a nice 20C so we set out for a walk with Fiona’s school friend from Exmouth, Hilary.

Click on the images for Hi Res or a slideshow

Hilary and Fiona in Bath

Fiona and  Hilary’s dads  were both in the NZ and British Army in Terendak Military Camp in Malaya when they were both about 8 years old.
This was the first time they had seen each other since then so it was a real occasion for them both.

Escape route for seagulls under the bridge
The shops on the bridge

We were heading towards the  Bath Bridge for a look and maybe have lunch around that way. It is amazing with shops and cafes all built on the bridge over a weir and a canal so the boats can pass on the Avon river below. Stunning place.

 

Back to the Abbey Hotel where we’re staying.

On the way back to the Hotel it was really nice to see people in deck chairs and just soaking up the views and the sun.

The Sunburnt Bumper

It seems at this time of the year, there is an endless demand on outgoing funds for the Motorhome.. Service, Insurance, COF and a rattle or two you’ve discovered that could be silenced.

This year, the big one was repainting the Bumper just to add to the list.

Click on any Image to enlarge

looks like a peely shoulder !

To be fair, a new vehicle where ever it is made should not have to have its bumper repainted after only 6 years so that grates a wee bit, but not being one to dwell on these things, it had to be fixed.

Before.. you can see the yellow tint in the lacquer from the sun.

The deterioration started about three years ago and when I raised it at the time with the dealers, I was told it came under the Fiat warranty which had by then expired.   ….Hey Ho as they say.. Lets get on and get it fixed…!

It started with the whole bumper going a yellowy colour and then the paint peeled off in bits. I progressively sanded parts of it to blend the colour and make it look a bit better as it got worse.

About to be taken off

After talking to one of my favorite RV repairers Peter at RV repairs who is also a qualified spray painter, he advised that I should leave it as long as possible so as much of the peeling paint would fall off and remove the need for a massive sanding job!

.. It couldn’t wait any longer !!

Click on the Gallery below for a Slideshow

In Devonport where I live, there is a great family run business which many of my mates at school have worked at over the years, run by Dennis  and Nathan Hale, called Fleet St Panel beaters.  They have a great reputation for doing things properly and are well known around the community as being really nice people.

In getting the newly painted Bumper. reattached

Where they are next to the supermarket in Devonport is pretty tight for big vehicles so it was a case of getting the bumper taken off and taking Rafe back home until the painting was finished.

All sanded and primed.

The bad news came on day 1 when after taking it off, we found that the bumper was actually fiberglass, not plastic. This meant it couldn’t be dipped to strip the paint off and they couldn’t bake the new paint on. It also needed to be sanded thoroughly before applying a special primer for the fiberglass. The good news part of this is that fiberglass is really strong.

Sanded and ready for some colour

Nathan was telling me it they budget on a couple of hours to prepare a plastic bumper. This one needed a day and a half of sanding as a lot of it was by hand. .. I could see my budget being blown sky-high and Fiona giving me a stern talking to 😐

All finished and waiting for Rafe – pic by Nathan

Unfortunately, they had a couple of staff off sick  and with the extra preparation, the 4 day job turned into two weeks but the outcome was well worth the wait. The finish was just sensational.

Although I was given the German paint codes, Kris the painter used a fancy machine that could read the colour off the side of the van and match it wirelessly to paints in NZ that can deal with our UV.

All done .. – WOW – pic by Nathan

An amazing colour match and friends who have known the van from new and know a bit about paint reckon it looks better than it was at the beginning.. I agree!!

Yes, it cost a bit more but I’m not complaining with such a great paint job.

Looking really good.. also with the polished headlights.

I’ve ordered a new logo sticker from Dethleffs and have my friendly local signwriter Tom putting the blue and white decals on over the next few weeks.

Wow

New Batteries ..maybe before time.

Isn’t it funny how as you go through the various upgrades on your Motorhome or Caravan and someone tells you, “buy this, its the best there is” and you say to yourself later “more homework was required!”

In early 2018, I did just that and bought some new batteries which were then the best thing since sliced bread as they had a new fangled silicon plate system.

Click on an Image to Enlarge

Not long after I had them installed, I took Rafe back to get the new batteries load tested as I thought they were dropping their voltage too quickly but they passed with flying colours.

Over the last few years I’ve persisted with them and we’ve found ourselves being plugged in to power more often than we’d probably like to prevent  voltage range anxiety.

A nameless friend and battery advisor has  explained to me that the batteries I had, due to how they’re made were  not  known performers as house batteries for Motorhomes.

So here we are only 3 and a bit years later replacing them with Champion Deep Cycle AGM’s from AA Solar in Silverdale.  With the NZMCA discount, these batteries are known performers as house batteries and are quite a bit less expensive than the 3 yr old ones I’ve replaced.

The empty space under the seat for the new batteries after the old batteries were removed.

Thorsten was the technician on the job and got into taking Rafe’s seat out to get at the batteries underneath.

Thorsten re doing the cables for the terminals.

Out they came and with a quick test, although they had lost a significant amount of power, they were probably ok as low load crank batteries for a year or two. I made the decision to dump them as I could see them sitting in the back of our carport in three years time 🙂

Just about done.

In went the new batteries.. the new Champions were a bit longer but just fitted in under the seat. Thorsten took one look at the wiring for the second battery and declared it to be vastly undersized.. so he replaced this with colour coded heatshrink and new terminal bolts.. very tidy.

I was really pleased with how it went with the wiring and the batteries and am now looking forward to now being able to be off grid a bit more than we have with known performing, Deep Cycle batteries.

All done !

With the new wiring and all cleaned up it really is a big improvement just looking at it and it almost seems a shame to cover it all up with the seat 🙂 Thanks Thorsten for a really tidy job.

Cracks in the Shower

Now that we’re back in a house and no longer living fulltime in our Motorhome, we’re in a position where we can get on with some of the bigger maintenance issues we should have done earlier.

Click on an image to enlarge

Shower base showing cracks. Pressure on drain outlets.

One of these was over the course of the last few years, we’ve  been getting some cracks in the plastic base of the shower. I’ve been covering them in epoxy progressively to make sure water was not getting through underneath.

Shower base with cracks

Apparently this is not uncommon in both Caravan and Motorhomes and is caused by stress in the plastic due to lack of support from underneath the tray.

Friends of ours have an almost identical Motorhome to ours  have had exactly the same issue so its a common problem.

Wall linings coming out.

Having just had our Truma heater dealt with by Peter and his team at RV repairs and with Peter’s background in boatbuilding, I thought he’d be the perfect man for the job.

Initially Peter was talking about adding some glass matting to the under side of the shower tray to add some strength to the tray but once he opened it all up, that idea went out the window in favour of rebuilding the base to make it better able to deal with the load.

Shower tray removed.. easy to see why it cracked.

Fortunately, there was no sign of any water or moisture at all underneath so I was really pleased about that… my epoxy repairs paid off.

The base was basically a pedestal made of ply supporting the inner two thirds of the tray and not very well.

Peter changed the top to make a thicker plastic top which went right to the edge of the hole, drilled new holes for the waste (in the right places!) and then glued it all together.

With the base out ready, sides cut down waiting for new plastic thicker top

It wasn’t a simple job as all the lining had to be removed to get the old shower tray out and to complicate matters, our bedroom TV was bolted through one of the shower linings up high so that had to come off too.

New base supported properly
All done and solid as a rock

And .. murphy’s law, after 4 days of sitting in Peters workshop, he couldn’t get it to start! The start battery had finally popped its clogs after 6 years of faithful service so Peter jump started Rafe for me to go and get a  battery … do not pass GO, don’t stop for the $200.. straight to the battery shop 🙂

The new Monstrous Battery

We went away last weekend in Rafe and the shower feels completely different.. much firmer and absolutely zero movement. Peter has done a fantastic job.. and thanks for the jumpstart 🙂

Cleaning those MPK vents

As time marches on, things in a motorhome and caravan need to be cleaned and one of the trickier things to clean is the little MPK roof vents normally found in most showers and bathrooms in your motorhome.

Click on any Image to enlarge

Yuk… grubby vent

While you’re taking these out to clean, its a good idea while they are out to replace and broken catches that have lost their tabs like two of mine had.

I had the good fortune to have a friend Bruce who had replaced his so he knew exactly where to get some replacements. Moutere Caravans have packets of 4 for $30 plus a courier so well worth getting before you start.

The torx screws on the arms

I also went to Bunnings to invest in a Torx screwdriver kit which is like an Alun key set which was very useful to get in the tight spots on the vent.

Getting underway….. After starting on the inside by undoing the 4 Torx screws holding the arms to the motorhome and then gently lifting the vent off the roof, I moved the whole assembly to the kitchen table.

Dirty vent on its back ready for dismantling.

Out came a bucket of Sunlight dishwashing liquid in a bucket and a soft cloth.

With the vent on its back facing up on the table, I could easily get the Torx screwdriver down through the handle at each end to remove the screws holding the handle onto the perspex. It also holds the plastic inner to the perspex outer cover so expect it to all come apart at that point.

The Torx screwdriver to get at the handle screws

It makes it really easy though at this point to gently prise out the catches for replacement and give the whole thing a good clean. I got some replacement springs too so replaced those as well.

I replaced all the catches as the ones that weren’t broken were so brittle with the sun that the tabs broke anyway as soon as I tried to remove them.

Tab missing and catch!
One with a tab still!

Be careful with the perspex outer cover as it can scratch really easily.

The new catch ready to go
Sliding in a new catch

As you re assemble it, be careful not to over tighten the screws as you will strip them in the plastic.

All clean ready to reassemble.

The whole process took me about 2 hours from start to finish and it makes a really big difference and the look when its all back together… there’s also something nice about doing it yourself too!

All done and clean.

After 7 years of neglect on our roof, my whole vent was a different colour and as a result, lets in a lot more light.

Nice and clean and back together.
Its a beautiful thing !

Two Fat Bottles

Don’t you hate it when you’ve just filled your LPG bottles up when its a mission to squeeze it back into the Motorhome LPG locker!

Not much room to come and go on.

I was in having some work done on Rafe and Peter the Engineer said “what’s that tape measure doing in your gas locker?” ahh says I. That’s for when you get to an LPG station and you discover that your LPG bottle has expired and you need a new one and making sure it’ll fit in the locker.

The bottles can vary in diameter around the waist by up to 10cm each ! With two bottles in the locker, that’s the difference between getting them in or if you can get them in together, being able to shut the door!! Who would have known !

Bottles in their locker

I found this out the hard way the first time, by just trying quite a few bottles to get two that fitted in the locker together.

Its is so much easier to get them in and out too.

Locker safely locked up.

Truma Trauma

About two months ago we suddenly found that our morning ritual of having the hot water heater come on at 7am to heat the water, and then switch over to take the ice out of the air,  stopped working.

After reading up on some online forums, I found the most likely cause was that  one of the two 900w elements to have failed.  The gas was working perfectly and it still worked on power but just ever so slowly.

Click on an Image to enlarge

The Truma on the Truma test trolley

The van was due to have its annual check for water ingress so I asked one of the really busy techies there to check the resistance on the elements. They were both the same.. strange.. if one is blown, it will have a different resistance reading.

A couple of weeks later, I took Rafe to another RV workshop where I was told there were a couple of “clever truma people” who would sort it for me.  After a week of having the van and removing the heater, cleaning and reinstalling it,  it still wasn’t working.
A big disappointment !

Back to square one.

The exploded element

So.. time to find a Truma Guru and  get this fixed once and for all..

While we were in Wellington recently, we were in a shopping mall and Fiona was doing the shops. I was sitting in the “husband waiting chair” .  I got on the phone and via some friends, I was put onto Peter Webster  who owns RV Repairs who are just up the road  in Albany.. yippee!

Peter W with my old Truma

Still sitting in the “Husband waiting chair” I called Jan at RV Repairs and booked Rafe in for some heater surgery.

After taking Rafe up on a Saturday morning, Peter’s electronics man, a really nice guy also called Peter, who tested the heater with an amp meter found it was only pulling just over 1 amp on full bore.. it should be pulling about 6-8 amps. So he started to take the unit out of Rafe and stick it on their specialist Truma test trolley.

The break

Within an hour, I got a phone call saying that one element had a normal resistance, the other was as dead as a dodo.

After trying to take out the old element, they found the element had virtually exploded in the heat exchanger and when it went, it had damaged the heat exchanger.. two choices,  new heat exchanger or new unit.

My stuffed element

Heat exchanger $2000 plus odd with two elements. There would be several hours to install the heat exchanger in the heater on top of this. The other choice was a new Heater unit .. mid/late $3000’s. I chose the heater. At last the thing will now heat properly again 🙂

Truma’s new policy for replacement elements is to provide a heat exchanger with two elements due to installation failures!

How a new element looks when being installed in the Heat Exchanger

I was absolutely rapt with the two Peter’s getting straight in to solve the problem without any fuss.. They’re clever guys too . Peter W (the owner) is a boat builder and spray painter by trade and the other Peter an aeronautical engineer so they’re perfect for solving a Truma heater problem 🙂  and with lots of knowledge left over !

They’re also motorhomers themselves and great fun with not just two Peter’s but three.. 🙂

The workshop is HUGE

Bent Keys

We were just about to pick up our Grandchildren and take them down to Rotorua for the last weekend of the school holidays when a fault came up on the dash that I hadn’t seen before.

Click on an Image for Hi Res

It was an image of a door and a padlock in orange and prevented the motor from starting. It would turn over with the key but never fire.

The key code fault

Out came the Fiat handbook which said the fault was related to the key and the code that needs to come from it and go to the engine management system. If it persists to check with the dealer.

I tried taking the key out and putting it in the opposite way and the engine started straight away.  I thought this was a bit scary so thought that given we were about to take the Grandies out of town, we should get it checked out, so off we went to the Andrew Sims Fiat service centre in East Tamaki.

The key in its incorrect position
The key in its correct position

After talking to their service manager Nick, he immediately said yep, its the way you’ve got the key in the ignition and you’ve solved the problem . It was all solved in seconds and I could relax  🙂

How the dash should look !

Because the keys flip out with the push of a button like a flick knife, the weight of my keys on the key ring and the fact that the lock on the key is getting a bit long in the tooth and isn’t what it once was, it is folding and preventing the code in the key handle from getting down the key to the engine management system. .. the answer… Take it out and put it in the other way so the key can’t fold and all will be well.

They don’t work when they’re folded.

So after 5 years of owning Rafe and running all over the country and never seeing this before, a new little thing to know about an ageing key.

The key in its straight form

Even one of the senior Andrew Sims guys there at the time wasn’t aware of it either, so we all learnt something new that day. If you didn’t know this, you could easily get stuck somewhere and not know that the solution was so simple 🙂

A happy Rafe with his key in the right way around!

Our Motorhomes new park

Over the last month or so, our Motorhome Rafe has been stored up in Albany getting covered in Motorway dust and crap from a concrete distributor close by so it was somewhat of a relief to be able to park it back at our house again and give the van a good wash!

Our house is one of three units on a cross leased section which run down the hill overlooking each other and then over the golf course. When I say overlooking.. just our roof but we’re at the top closest to the road.

Click on the Image to see Hi Res

It had a parking ramp here already but it was in the shape of a triangle and we all know that Motorhomes and cars for that matter tend to rectangular 🙂

Our neighbour Doug is a semi retired builder who is a magic guy and was happy for us to do whatever we needed to make Rafe fit in the hole.

Boxing

Enter Ryan and Ray, a couple of concrete experts who are good friends of my son Andrew to take on the project of adding to the existing pad to make it useable and also add another around the corner for an outside water cylinder and Heat Pump.

The project went without a hitch, even getting the concrete truck in to do the pour and the result is perfect.

Click on the Gallery below for a slideshow

Since then, the Water Heater and Heat pump have been installed and we’ve managed to get Rafe in here but not without some drama!

The first time in. I got a good friend of mine Alan to be my eyes and ears at the back to help me in. The first obstacle was a hump at the end of the drive which I thought would grab the overhang but surprisingly for me, there was never an issue.

Click on the Gallery below for a slideshow

The tight bends around the front fence were a bit of a problem and I managed to get the front wheels stuck in a small patch of grass behind our letterboxes!  After jacking it up and slipping some things in to jump out, it finally did but not without creating some stress and some mess of the grass.

Rafe stuck in the grass. Alans cell phone pic
Some of that fence has gone

Anyway, we’re in and it works a treat but I have decided since to convert a fence panel into a gate and add some gravel to make it a lot easier to get in and out.

Tighter than it looks

We also have a 16 amp socket going in to keep the batteries topped up.

Hot water and Heat pump in

Thanks to Ray, Ryan for the great concreting, Pete the sparky for his wiring and Alan, a big thanks for helping me get in for the first time.

The Motorhome Surgery

Just recently, I had the pleasure of having a guided tour through ACM’s Auckland Motorhome repair and manufacturing factory. Amazing stuff.

Click on an Image to see Hi Res

A decapitated Luton restored

ACM was started 7 years ago by ex boat builder Chris Cunard (think Super Yachts) as a repair facility and later added his own range of manufactured Motorhomes. After chatting to Chris for a while, you very quickly get the sense that build quality is the name of the game and you can see this everywhere you look.

Chris Cunard

One of ACM’s Leading hands Daryl, showed me around a couple of the new Motorhome’s they are currently making for customers. Apart from having their own standard models, they make bespoke vans for those with special interests or hobbies. They also do repairs for other dealers brands too.

One of those I saw was one made for someone who was confined to a wheelchair. All the benchtops were lower. There was a special hydraulic lift at the back for entry and the bathroom and bedroom was all specially fitted out so they could enjoy Motorhoming. Fantastic!

Room for the slideout with the wheelchair Galley

A lot of  slideouts in the industry are driven electrically. These ones have huge hydraulic arms to drive it instead which should make it a lot more reliable. The hydraulic drop down legs for levelling were huge too.

Click on the Gallery below to see a Slideshow

One of their clients who liked his music so much, they designed and built his Motorhome so that he could take a built in piano with him and it looks like part of the Motorhome.

Good on them for taking their hobby with them!

Click on the Gallery below to see one of the finished Motorhomes

Stairway to Heaven

Athough I was lucky enough a few years ago to have a look through the Niesmann and Bichoff factory in Germany, it was really nice to see a local builder building Motorhomes basically by hand, doing a really nice job of them and providing employment and skills training for young Kiwis.