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comjero

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Reply with quote  #16 
Hey Sharky,

Yes the side clearance light is the one you marked with a question mark and its a sealed unit but it seem they don`t seal the black part to the camper body and then the cable goes through the centre into your trailer will also need to be sealed. If your getting what appears to be condensation inside the lens refer to Anthony`s fix in a previous post.
If your going to fix these you might as well look at / fix the front ones on the `A` pillar as there probably not sealed either. As these lights are sealed units they prize out of the holder so take a bit of care, if your using a flat blade screw driver maybe tape up around the lens with masking tape in case you slip it won`t scratch your paint work, (the black part has 2 x flat head metal screws that attach it to your camper and the lens clips into it ) .
 The reflector you mentioned is normally fixed on with sikaflex so no holes through the body of the camper.
Good luck

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William the Conqueror

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Reply with quote  #17 
Hi Sharky

As Comjero pointed out, the lights I am referring to are the ones you marked with a question mark. There are three holes that need to be sealed to stop the leaks. As mentioned in a previous post, you need to remove the lens and holder and sika the holder down and then the lens into the holder. I would also seal the joins between the two coloured halves of the lens the CA glue (superglue) or replace with single coloured lens Ip78 rated LEDs.

You mention sealing the rubber grommet around the rear lights - probably more important is to remove the lights from the grommet and seal the wire harness as it is this that goes through the bulkhead. You will probably notice the plastic sheath covering the wires has a split along its length - it is this that lets the water through the grommet. You may even want to add a piece of heat shrink that seals the wire (extend it through the bulkhead) before you seal the grommet with sika.

If you can see evidence of water tracking near the reflectors, I would suggest that it is coming from a couple of places;

First, through the rivets holding the caravan track onto the trailer. Unfortunately sealing the centre of the rivet will not remedy this and the best solution is to remove the rivets, prise the track up and sika underneath the track (around the rivet holes and then re rivet (remembering to apply sika to the rivet before you replace it).

Second, the bolts that hold the jerry cans to the bulk head. These ones are difficult to seal by removing them - so the easiest way is to apply a cover over the entire bolt head. I use apply a blob and then press down with a gloved finger to make sure it sticks and then smooth with a gloved finger dipped in turps to make it look neat.

Hope this helps

Cheers

Anthony

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Sharky

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Reply with quote  #18 
Hi Camjero and WTC,

Much appreciated for the feedback. If I understand this matter (i.e. side clearance light) correctly :

1. Tape up around the lens with masking tape 
2. Use screw driver to remove the lens (between the lens and the lens holder [black part])
3. Apply sika on the black parts or any holes for electrical wiring running through this and attach black parts to trailer surface
4. Apply with sika and seal the joins between the two coloured halves of the lens
5. Apply sika to the lens and attach to the black part /lens holder

The explanation on rear lights and rivets holding the caravan track onto the trailer is clear.

S
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William the Conqueror

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Reply with quote  #19 
That will seal THAT leak perfectly.

If you are inclined, you could also do the two white clearance lights on the front of the trailer as well. If they are not leaking at the moment, I would probably leave them.

Cheers

Anthony

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Der Wutzl

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Reply with quote  #20 
Hi Sharky

In our experience no, but there appears to be very variable quality control on different vans.  We did have dust problems earlier that would also have been water problems in the floor but that appears to be fixed.  The seal around the spare tyre bolts/bracket on to the van were also non existant, but now fixed.

We recently forded a creek that was ~700mm deep (almost over the wheels) and we did get some water into the front compartment (not suprising since the seals on this are very poor and there is NO seal around the Webasto exhaust) and about 200ml in to the left rear compartment, the rest was dry. There were 2 other 490's on the same trip and maybe they can let us know if they had any water problems.

Hopefully you will find all of your leaks.

regards, Klaus




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Monstered up 2012 Prado Kakadu (chip, exhaust, lift, winch etc etc),  2013 UEV-490 Evolution
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comjero

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Reply with quote  #21 
Hi Der Wutzl,

I sealed my exhaust with sika firesil N its rated to 300 deg C, But its not quite touching the pipe due to the furnace sitting flush on the floor of the compartment its about 15mm away, you maybe able to get one that goes to a higher temp or you could modify it by fitting a marine exhaust through hull fitting. Looks like a short exhaust pipe with a flange in the middle you  can then clamp your exhaust pipe to each side and the flange can be sealed to the floor of your front box using either a high temp gasket or silicone style sealant hopefully no more water ingress.
That rear compartment could be the 50 mm square section welded under the main chassis rail it should be seal on the end as it has a 10mm hole in the front under side to let the galvanising solution out and its only stitch welded  on so it can leak where there is no weld also
Cheers
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Doyta

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Reply with quote  #22 
conq3.jpg 
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Doyta

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Reply with quote  #23 
conq.jpg  arrow marks the spot where a slight little hole was in sika. after fixing that hole stopped the leak on mine. its in the track.   a trick I used is spray water at lowest spot then check for leak, slowly getting higher.
Conqueror we replace your netting on roof under warranty. I found the did not sika flex the rivets under  the green track on the front which is where dribbles of water came in to wet the roof.
Like all camper vans there are slight issues.as long as the warrant it and are willing to help is where thing could go pear shaped.  Its good conqueror has now taken responsibility and warrant these issues. other than slight  dribbles at start it is now fully water proof and we are very happy with it

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Sharky

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Reply with quote  #24 
After all the fixes with sikaflex (info from above), I waited for the rain, there were some leaks in the bins both sides.

Anyway, I waited for dry weather and did a simulation of the rain by using water hose suggested by Doyta. Next, I then ran the water for 15 mins and let the water run down the top along the awning tracks and down the back all the way to the rear reflectors. No water came through into bins during these 15 mins. The leaks are rather 'illusive' if I may say. I will have to wait for the next rain. For this exercise, I believe I sealed all along the awning tracks and rivet holes. There were no leaks in the side lights/len holders.

Anyone have any further ideas or suggestion?

S
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Doyta

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Reply with quote  #25 
Could be coming down the chassis tube, check to see foam, another method is to turn blowed fan on and spray bottle with detergent check for bubbles
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William the Conqueror

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Reply with quote  #26 
Just remember if you are using the blower and soapy water method you will get some bubbles along the door/roof seals. It is normal and doesn't mean they will leak, it is only if you get excessive bubbling that indicates a problem.

You have to remember you are sucking air into the trailer through the blower and it has to go somewhere - i.e, out past the door and roof seals.

If you get bubbling in joints and rivets - these will need resealing.

Cheers

Anthony

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Sharky

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Reply with quote  #27 
Thanks for the suggestion everyone.

S
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Todd

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Reply with quote  #28 
An update from my original posts on this thread...

Took the 490 to Newcastle late last year to have the leaking issue fixed. The team had a skirt made up for me, and sorted the leaking issues, so happy to report that the camper is no longer leaking.

Although I would have preferred my original one piece skirting and walls, the separate skirting solution is palatable.

Thanks Anthony and Comjero for your help here.

On a side note, I met Peter Nasser at Newcastle. He mentioned he was spending $5 million on a conqueror facility in the Newcastle area. Interesting.

Cheers,

Todd 
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filbee56

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Reply with quote  #29 
Hello Todd,
WRT your comment on Conqueror expenditure in Newcastle ($5M). Pete Nasser has, for some time now, wished to set-up a sales/distribution office/workshop in the Sydney CBD. However, real estate is extremely steep and requires major investment in either purchasing or leasing of premises. Even out 'west' in the Sydeny burbs is staggering.
But when I last spoke to him at Christmas, he was still keen to persue Sydney real estate to give him (Conqueror) better exposure to the NSW market. Makes sense.

His Newcastle operations are very tight, so could really do with more room. 

All the best, Filbee56 


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2013 LC200 TTD Sahara - Ex-Demo 10/2014 UEV-490 Evolution with the lot.
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