Leaking Rotten Bailey Caravan Repair

Leaking pre-2008 Bailey caravans are not rare. This slideshow is intended to help anyone who has discovered a similar problem with their van. Once again my thanks to Rob Shearer - without his video, I wouldn't have known where to start: -
Rob's video - • Bailey Pageant Leak Re...
Materials
Seals+Direct really know their stuff and were very helpful over the 'phone.
Window seals from Seals+Direct Ltd - www.sealsdirect.co.uk/seals-p...
Wallboard available from O'Leary Motorhomes - www.olearymotorhomes.co.uk/

[@normandylife3587]

I mention Rob Shearer's video and how he inspired me to have a crack. He has just made an update video which is well worth looking at: - kzbin.info/www/bejne/gWXTmI16fJp9b6c

[@72PSI]

Thank you for sharing this. It was helpful and very peaceful to watch with the music choice.

[@alancraigie7951]

Thank you so much, you video has given me hope that I can repair my caravan. Spent £8k and the whole front end windows are rotten. Your video has as I say given me hope. 👍🏻

[@robgrant1540]

I have a Bailey Senator which has exactly the same problems. I am just stripping the rotten bits out and have reached the disheartened stage. Looks like a lot of work ahead of me. This video really helps though. Thank you.

[@normandylife3587]

It's not so bad once you get stuck in! Good luck.

[@florinsmolnicki9747]

Thanks to Ian and Rob for your presentations!

[@runningpanda6570]

Just Brilliant! ....Thank you for being so kind to share your skills in taking on such a daunting rebuild for most novices! ...I'm going to give this a go on my Bailey Ranger 2001 that has the same splits in the front above the windows.My whole front panel was replaced after on our maiden voyage a recovery truck reversed straight through the front on our very first outing. Bad experience, yes, but because the people on site (other caravanners) were so kind and helpful and one of them wrote a statement even without me asking to help with the claim against the reckless driver...Needless to say we were hooked for life to this very day:)

[@normandylife3587]

Thanks - that's very generous of you! Good luck with the repair. That sort of accident must have been horrible and could have put you off for life. As for tackling the job - I am merely a reasonably competent DIYer and I think this sort of work is achievably by anyone who can bang a nail in straight. What shocked me was how flimsy the construction of these caravans is - which means it's not hard to do a better job than the manufacturer. Do look at Rob Shearer's videos (there's a link to the most recent in the top comment). He was the one who inspired me to have a go. KZbin is wonderful for this sort of stuff!

[@tedcase9175]

these presentations are fantastic got a leak on my ABI static caravan, not the same but similar,now to wait for spring, lock down lifted and away I go,thanks giuys

[@normandylife3587]

Thanks Ted - good luck in the Spring!

[@kwackman]

Well done on a superb repair, it looks quite a but worse than mine was. I am so pleased to have inspired you to go ahead with it and thank you for the credits you have included in your KZbin video.

[@normandylife3587]

Thanks Rob - you're right, it was worse! I was despondent having discovered how bad it was. Your video was truly a life saver. I'm glad, too that this lock down has given me the time and motivation to do my own video. KZbin and Google have transformed our approach to problems. They are now a first port of call and so many people have taken so much time to share their knowledge and experience, what was hidden before is now widely available. I'm only to happy to have been able to make a minor contribution. If you ever drag your van across the Channel to Normandy, come and compare notes!

[@mikekeith2474]

Not a Bailey owner but a very interesting and informative piece of work, excellent thanks.

[@IanHaywardCalvados]

Thanks Mike - and for taking the time to comment. I'm afraid it's a problem for quite a few different makes, as other videos show.

[@Grangeservicesag]

Just a quick thankyou for sharing your experiences of repairing your Bailey. I have used the practices and tips you have given to rebuild the front of my Bailey ranger over the last few weekends. Thankyou so much for sharing as it has been a massive help. 👏🏻👏🏻👌🏻👍🏻 Pete

[@normandylife3587]

Thanks - glad it helped

[@StevieD445]

I would like to thank you for making this video which helped me a great deal when I had to make a similar repair to my own Pageant 5. Both of Rob Shearer's videos were a great help too

[@IanHaywardCalvados]

Thanks Stevie - glad you succeeded.

[@philtebble4390]

Very skillful job my friend 👏

[@LuckiesLife]

What an absolutely superb video! I am leaning closer and closer to doing the work on the windows and bathroom of My Senator Wyoming 5 and this video really helps bolster my confidence. Thank you.

[@normandylife3587]

Best of luck Graeme - Rob Shearer's video did the same for me!

[@leonarneil]

How did your repair go? I think I have a similar issue on my Indiana 5. Stays for the front blind runners have came loose and indications of rotten top batten.

[@paulk1322]

I liked the slide show, it was very interesting. Had to do the front window top piece on my Avondale Dart.

[@emmasbuffday6645]

Thank you for such a great video it has inspired me to have a go at my own.

[@vdub8567]

Excellent work sir 👌

[@IanHaywardCalvados]

Thank you kindly. You're clearly a gentleman - and there's damned few of us left!

[@ct026]

I’m hoping this is all I have to do with our van. Only had it three days. I thought I had checked everything before buying it, (privately) buy alas..... Great slideshow and well within my capabilities.........just need to find somewhere to do it! Thank you for sharing.

[@normandylife3587]

The trouble is the wall is so covered by the blinds, fly nets and curtains you can't see behind. Easy to miss - a warning to all of you looking for a used caravan! We were lucky to have our lean-to to do the repair. If you can't find space under cover, I think I would buy a cheap garden gazebo/marquee. They're cheap as chips on Ebay and you could cover up the front end while you work. Best of luck!

[@adamandmusty5966]

Amazing work!

[@samaeybelgium]

Well done.We don't always need to call the industrial instances to repair our things.We can help ourselves too.LEss polution!

[@carolinenye3402]

Excellent tutorial thanks🙏🥰

[@karencurtis6141]

Fantastic job 🤗

[@a11csc]

super repair and you saved a small fortune i bet

[@IanHaywardCalvados]

Thanks Chris - probably around £4K I would guess, given how bad the damage was. Sadly we decided discretion was the better part of valour this year - and stayed at home. We really didn't fancy sharing 'les sanitaires' in Covid France. They are generally spotless - but it's not the spots we were worried about. Here in Calvados there is but one person in hospital and nobody in intensive care, thankfully. Rather different to the somewhat hysterical news coverage.

[@elsaearl6450]

Same van, same problem! Just completed the repair but used pressure treated wood for the surrounds, 22mm, and glued/screwed 9mm ply over all in one piece. 36 screws! Should be strong enough. Used 35mm seals from Sealsdirect. It was a case of repair it myself or scrap the van, probably have cost thousands at a dealer.

[@martinredfern9130]

Many thanks for this great video , I have also watched Rob Shearers one and between the two videos there is a lot of great information and tips and also links to suppliers ,I will now tackle mine ,a Bailey Senator Indiana S6. I had it done by a so called professional 3 years ago and it went again after the warranty had ran out, cost over £1500 also, so being a keen diy’er I’m going to have a go myself. I unfortunately don’t have a covered area to do it under so will be tackled on my driveway. I may even do my own video . Wish me luck.

[@IanHaywardCalvados]

Only too pleased it has helped Martin - and the best of luck! If you want any specific advice, drop me a line and I'll help if I can. This chap repaired his on his drive - kzbin.info/www/bejne/r4W6aXqXjpWjoNU. Looks like he had a sheet of clear plastic taped over the front. You might also invest in a cheap Garden Gazebo/Marquee to put over the front and keep the rain off whilst you are working - they're on Ebay from under £30 - and you can use it on the back lawn afterwards!

[@martinredfern9130]

Ian Hayward Ian ,well ive started on my Indiana and surprised how quick its been going . Luckily I have only got to do the left side again , the side the so called professionals did 3 years ago, all the rotten wood is out and replaced with pressure treated timber all glued into place and nice and solid. Everything is cleaned up ready to reassemble,only taken a day. Ive ordered a wall board and some sikaflex and have just got to order the rubber trim. Can you remember the size/code of the trim you ordered from seals direct. I’m thinking that its the 35mm on ,although the wall only measures about 32 mm . Hopefully if i get it all delivered this week ,and we have a dry weekend next week, I should get it all done no problem .many thanks ,Martin.

[@IanHaywardCalvados]

Hi Martin - I've just had a look at the Seals Direct site and if memory serves it's the 35mm CS4091G for grey andCS4091W for white insert. Give them a ring to check, they'll know which it is I'm sure. When fitting, cut it too long. You can always cut more off, but you can't stick it back on!

[@martinredfern9130]

Ian Hayward cheers , it’s the one I was looking at , with the grey insert. Did you get 8 m and if so was this plenty , going to get the tool to insert the strip as well , should make it easier. Many thanks ,Martin

[@IanHaywardCalvados]

Yes and yes - from memory and if I were you I wouldn't rely on it! I think Rob Shearer ordered 8m, but run a piece of string round each window and measure just to check. That's easier than using the tape direct on the windows. The silicon spray made a big difference to sliding the trim in, so get a tin of that too.

[@florinsmolnicki9747]

As far as I can see, the Bailey caravans have all the problems with the front panel. Let's forgive them, the caravans they built are beautiful !!! The configuration inside is extraordinary. The bathroom is huge, separate shower. Bailey caravans are a gem !!!

[@SAXONWARLORD1000AD]

no good being a gem to look at if they're rotting away from the inside - due to poor construction techniques

[@rogersmith5167]

The biggest load of badly made junk on the road, how they are still in business amazes me.

[@TrevorBlevins]

Great video. Let's me know what I am in for now!

[@IanHaywardCalvados]

Best of luck! Let us know how you get on. I'm no master carpenter just took it slow and steady.

[@jimbeaver1815]

Hi. Thank you for posting this excellent tutorial. Stan, our van, has the same problem and I'm going to have a go at fixing it with the help of your vid. One question, when removing the original timber I assume that it will be glued to the grp(?) outer skin?? If so, how do you break any bond and clean up residual adhesive?? Thank you

[@IanHaywardCalvados]

Hi Jim - to be honest mine was so rotten it just fell away! Because of that, I'm not sure there ever was a bond between outer skin and woodwork. I have a very old, much favoured paint scraper/filler knife which has an edge like a razor these days. Excellent for scraping off surfaces (as long as I don't dig it in). I've always found white spirit excellent at cleaning up sticky residues. A combination of the two for shifting stubborn bits. Petrol would work, but perhaps a little more dodgy if you're a smoker! Alcohol is good too. (Isopropyl rather than what you have in the drinks cabinet). I followed up with meths. Again, all these solvents tend to be highly inflammable, so be cautious and work in a well ventilated space. Good luck, let us know how you get on. I'm a DIY'er and no master carpenter but took great inspiration from Rob Shearer - it's really not that tricky - and whatever you do will be better than the original!

[@jimbeaver1815]

@@IanHaywardCalvados Hi Ian Thanks for your prompt reply and tips therein. I plan to start the project at the end of our caravanning season - around mid October. I don't want to tear it all down and get stuck and so miss even more of this season. I'll let you know how it goes in due course! Thanks again. Regards, Jim

[@GaryB_OutandAbout]

I’ve just found some soft/split ply and wallpaper inside on one corner of a window of our Bailey Pageant 5 series and of course the small hairline tell tail cracks all above the window rail.. this looks doable.. and after watching, I may give this a go. Great video 👍🏼 I assume you never bothered re-papering the interior and just left painted?

[@IanHaywardCalvados]

Sounds like you may have caught it earlier than I did, which will make life easier. Good luck!

[@brianmccarter6448]

Hi great video thanks for the inspiration to tackle mine were you able to repair without removing all the internal overhead lockers. I’m worried removing them will effect the structural integrity of the van and might be a nightmare to replace.

[@IanHaywardCalvados]

Brian, sorry to be so long in replying - I've been working away. No I didn't need to take out the top lockers but even if you do, I wouldn't worry. I'm sure that replacing them will restore structural integrity and nearly everyone here who has effected repairs has built back stronger than before and I've no doubt you could do the same. Spent a good part of my youth working on wooden boats and I was really shocked at how flimsy these caravans are.

[@schuur10]

I got myselfs a Beyerland Vitesse 470T from 1992, i need to change only front window rubbers now

[@jr5389]

Yip mine too, leaking from the day it was built 1991 👍🏴󠁧󠁢󠁳󠁣󠁴󠁿🤪

[@IanHaywardCalvados]

Not their finest hour was it - hope you get yours fixed.

[@garymcclelland95]

The plywood did you use marine plywood or standard also window rubber what size I'm abit confused with that thanks great video my baliey is the same gona do the work myself

[@normandylife3587]

If you are in the UK you can order the original wallboard from www.olearymotorhomes.co.uk. I just used ordinary plywood from the builders' merchants - 3 or 5mm - both are fine. It's all covered by the curtains, blind runners etc in any case. I can't remember the seal part number, but measure the final wall thickness (outer skin, wood frame, inner plywood skin) and choose accordingly. It was around 35mm. Talk to www.sealsdirect.co.uk/shop/category/caravan-motorhome-window-seals-515 they'll be very helpful. Or look at the technical drawings on their website and compare with your old ones.

[@mariomangion933]

Hi, thanks for the video, have same problem. Just wondering if a sheet of marine ply could be cut out for the window openings instead of individual timber pieces? What thickness was your timber? ( if possible would like to puchase sheet before stripping out) Thanks.

[@IanHaywardCalvados]

Not sure that would work - see my reply to Jay Dee below. Total thickness (GRP skin, wooden frame, interior 3mm ply skin) is around 35mm. Take off 2 or 3 mm for the GRP and you'd need a sheet over 30mm thick - which I imagine would be hellish expensive, particularly as you are cutting out and not using the majority. It would also be too stiff to conform to the slight curve of the front of the van and would distort the shape of what is a very thin and very flexible GRP skin. It would also be very difficult to manipulate into place. Thickness of wood? See replies to Thomas Edwards below. A mm or 2 either way will not matter - the window seals are flexible enough to allow for small differences.

[@JayDee-xj9lu]

Hi. I'm about to do the same job as I just bought a Pageant with the same problem. I was thinking of using a full sheet of 22 mm ply and cutting out the window and not using a 3 mm cover sheet. Is it flat enough to do that do you think? Thanks for a great video, and tips on sealant etc.

[@IanHaywardCalvados]

I think you'll struggle - there's a curve right across the front and 22mm won't be too keen to bend! The GRP front is very flimsy and won't offer sufficient stiffness to clamp and bend back to. The framework that's there is very easy to replace and will be far easier to fit - and cheaper too. And you'll only need to replace what's rotten or soft. Hope that helps.

[@JayDee-xj9lu]

@@IanHaywardCalvados Thanks for that. I have the front of the van lifting up and down by 4 inches. Scary. The chassis is bending sideways as it does. What really hold the front to the floor? All the brackets inside the boot is loose. Surely that's not what holds the front down. The chassis should be stiff enough.

[@diananorth6544]

Thank you for your video ,its really helpful. I have a similar problem with my Lunar Lexon 2008.,which i am now planning to tackle, Can I ask what type staple gun did you use. The staples need to be about 12mm long and I wondered whether a manual gun would have sufficient energy in it for this length of staple or whether i need to purchase an electric gun ?

[@normandylife3587]

I had to have a look through to remind myself. There's a picture at 9.06 of the cheapy pneumatic nailer I bought at Lidl's (it's still going strong) which I used with brads on the wooden corners, but I used a Stanley stapler for fixing the windows seals. You can see it lying on the front shelf at 10.24 next to the torch and the staples are visible in several pics. They do take a fair amount of pressure to get them to work, but I've had it for years so just used what was to hand - and it coped well. The wood I used was only pine so easily pierced. Not sure old age and arthritis would let me do the same thing now! Hope that helps.

[@diananorth6544]

@@normandylife3587 Many thank for the reply that's given me the confidence to buy a heavy duty manual Stanley stapler to do the job. I can get one from Screwfix in England for about £24 which will take up to 14mm long staples which should be OK for fitting the rubber window seals onto the pine frame

[@thomasedward9065]

Hi I'm going to do my Bailey soon i hope could you tell me the thickness of the wood used for the frame and could you tell me the corner glass you used has the tin is in French and any info on how you made the board at the bottom has ive watched it but I'm still not sure how to do it thankyou and great video sorry it's a long question

[@IanHaywardCalvados]

Hi Thomas - wood thickness, I can't remember. Around 26-27mm? I don't suppose a millimetre or 2 either way will make much difference. Just measure the good stuff you leave behind (or the bad stuff you remove) so you can match it. The total sandwich (outer skin, timber, interior wallboard with the glue/sealant layers) needs to be about 35mm - which is what the replacement window seals are sized for. By 'corner glass' I'm guessing you mean the fibreglass resin. I just went into the local auto parts store and took it off the shelf. Isopon is a UK brand name I remember. Do a search on Ebay for Isopon fibre glass repair kit and you'll turn something up. (You will - I just looked!). Unless your shell is badly cracked (like mine) you won't need to fibreglass it. As for the shelf - I don't know what I can say that the diagram doesn't show better. The old shelf butted up to the wallboard ie the wallboard went down behind it. In my version, the shelf goes under the wallboard and butts up against the inside of the outer skin. I fixed the cleat on top of the shelf to have something to attach the wallboard to. Hope that helps - good luck. Martin Redfern on here might be more help - he's just done his Bailey and will have more up to date info.

[@thomasedward9065]

@@IanHaywardCalvados thats great thankyou ill see if i can get it done in the 2 weeks im mebt to be away in July unless they don't lift campsite restrictions but if they do ill go away in it and do it another time its not leaking in which is a good thing has i think they fixed the leak ie the same area has yours but they didn't replace the rotten wood ill keep you posted and hopefully post a video or pictures ill be intouch if I get stuck do you have a other means of contact if that's ok thankyou thomas

[@peterhyned5400]

hi thomas the wood is exactly one inch thick, which was a problem here in ireland as its metric, so i bought a window board from hardware and got a mate of mine to cut and plane it to size.. hope this helps

[@shawwaytofitness]

With fibreglassing the external wouldn't that have pushed the window rail and window out from the rest of the panel? How did you over come that? Larger window seal?

[@IanHaywardCalvados]

Sorry Shaw - only just spotted this. Doesn't seem to have caused a problem - we're only talking about a millimetre or two. You do need to sand down the substrate to give a good key, so there is a good bond formed but the window seals work fine.

[@toxtony]

Hi Nomandy Life, question about the seals, how you bond or weld the 2 head of the seal together?

[@IanHaywardCalvados]

I didn't - cut them so they snug up tightly together. I suppose you could add some glue to the join, but I didn't do that and I haven't had any problems.

[@florinsmolnicki9747]

Ian, where can I buy wallpaper, just like the original one? I have a Bailey Champagne caravan from 2003. I also have to repair the front window / panel. In the end, I want to put wallpaper like the original.

[@normandylife3587]

The wallpaper is an integral part of the wallboard. There's a link to the suppliers - O'Leary Motorhomes - above.

[@Kevin-tc3ob]

hello what size coner beading did you get please

[@normandylife3587]

Honestly can't remember Kevin - 5-10mm quadrant? Depends on how big a gap you leave I suppose!

[@kitbag1]

Hi I’ve this to do can you remember what thickness the framing wood was thanks

[@normandylife3587]

Could have sworn I'd replied to this! However - you'll find my answer in a reply to Thomas Edward below. In short 26mm? Around 1 inch? Measure what's there is the best solution.

[@harryb8476]

Imperial - 1" x 3/4 see my other comment on doing a similar repair this month..

[@adrian415213]

What size timber did you use ?

[@IanHaywardCalvados]

25mm from memory. Measure what's there (if there is enough left).

[@peterhyned5400]

you inspired me to have a go at my caravan, i have everything removed , same problem holes in window rail not pre drilled. my caravan is a bailey oklahoma 2007 , series 5 , i am stuck as to what size seal i should order, can anyone help , video is a god send ,, thank you.

[@IanHaywardCalvados]

Hi Peter - glad to have inspired you!. I would give Seals+Direct a ring (there's a link to their website above). I'm sure if you tell them the year and make they'll be able to help. They were very helpful when I rang them.

[@peterhyned5400]

@@IanHaywardCalvados thank you Ian, i got the seals from seals direct, they were helpful, i am a bit concerned the mastic looks very thin, did you use it as it came or did you add some, thank you, Ian.

[@IanHaywardCalvados]

I used it as was. Took them on trust that they knew more than me! No problems for me so far.

[@peterhyned5400]

@@IanHaywardCalvados THANK YOU VERY MUCH IAN. i am coming near the end, thank god seals are on , tried the gadget from seals direct for fitting filler strip what a waste of time that was, i have been working with tools all my life and thought this thing would be magic i have to say it was rubbish , would not advise anyone to order it, as a matter of fact it should come free when you order some seals, but fitting a piece of garden string on outside lip of rubber is a breeze,, sorry for going on i just think its a rip off for something that looks like it cost penneys to produce... again i thank you and hope yours and my story inspires others,, god bless.

[@billcochrane6044]

@@peterhyned5400 It's strange how different people have different opinions about the same thing isn't it. I'm right at the end of this same job and bought the strip fitting tool with the new seals and some silicone lubrication spray. It made a difficult and annoying job extremely simple and speedy,( 5 minutes max each window). I found the secret was to apply firm, even pressure to the tool against the channel ensuring that it was not allowed to rise out of the seal at any point. Did you use lubrication? If not the tool will not slide at all. Although it was expensive for what it is, it did the job perfectly for my 80 year old arthritic hands when used correctly. Although I probably won't use it again before i snuff it, I consider it money well spent. And may I just add my appreciation of this and Rob Shearer's posting of two first class videos.

[@paulwylie4331]

We have a 2005 Elddis Avante 636 which we have just purchased privately as seen! I was cleaning it up today and noticed a loose front window catch. Hey hoy the whole frame is rotten. Looked under the top of the gas locker and the front sill is falling apart in places due to rot. Felt pretty sick at first as we paid £5200 for a decent looking van and now that! However after watching your video and Robs I feel I can give it a go myself. Did you just glue/seal the wood to the shell with the sikaflex - no nailing or screwing? Cheers?

[@paulwylie4331]

And how long did it take you?

[@paulwylie4331]

Watching Robs video it seems he didn't bond the new frame to the GRP but I cannot work out he fixed it in place?

[@IanHaywardCalvados]

Paul - sorry to take so long to get back to you - I've been away and offline. The front of the shelf - I didn't fix that to the GRP outer skin - certainly didn't nail or screw it. There are brackets to the left and right (5.05), a central bracket (5.14) and the exterior handles fixed to it too. It is also screwed through from the interior upright wall - you'll see I added extra stainless steel screws (5.21) that are hidden by the wooden corner moulding I put on. How long did it take? Depends how bad it is really. Looking back at the photos - most of August! Mind that wasn't all day, every day - we were trying to have a holiday too! The trouble with these jobs is that they are all about doing new stuff. If I were to do it again (God forbid), it would be much quicker because of the experience gained. That's what is so great about KZbin. Rob's video was an enormous help to me and I made this in the same spirit - hoping it offer help and guidance

[@ilovebrean]

This is what needs doing to our caravan :( but sadly we aren’t in a financial position to do :(

[@ilovebrean]

You are very talented

[@thomaspridmore106]

So many baileys on the market i now no why clad I don’t own one

[@Pidge0386]

"immaculate condition"