Caravan Repairs: My Experience with GRP Maintenance and Jockey Wheel Replacement on a 1998 Model
In a recent acquisition, a 1998 Bailey caravan purchased from Facebook Marketplace came with a few challenges. The jockey wheel was noisy, stiff to operate, and long overdue for maintenance. A closer inspection revealed a crack in the fairing of the caravan, which was the worst of the damage.
To tackle the issue of a damaged jockey wheel, the decision was made to research ways to restore it to health. The jockey wheel assembly on the caravan was clamped to the outside of the A-frame. A wider jockey wheel was considered as a potential solution for easier movement on softer ground.
For those embarking on a DIY jockey wheel replacement, securing the caravan on level ground with the handbrake engaged and wheel chocks in place is the first step. Loosen the wheel nuts if changing wheels, then remove the pin or mounting clip holding the jockey wheel in place. Slide out the old jockey wheel and replace it with a new one, securing it with the same pin or clip. Affordable alternatives for a new jockey wheel include models that combine hydraulic jacking with jockey wheel functionality, or simple standard jockey wheels with adjustable clamps.
Work on the A-frame was required for the caravan, and a plywood plinth was made to support the leading edge of the shelf in the gas locker. However, this modification reduced the space available for the A-frame fairing by 20mm. To repair the crack, strips of tape were placed as a guide for a jigsaw to trim the trailing edge of the fairing. The fairing was then repaired by grinding along the line of the crack to create a V-shaped channel, filling it with gel coat, and allowing it to cure.
Aside from the crack, there were shallow cracks and light damage in the gelcoat top layer of the piece that required repair. The jockey wheel, once replaced, was found to have a definite buckle to it, but it was better than the old one as it spun freely. The jockey wheel assembly, including the noseweight gauge, was in need of greasing and tidying.
For those who prefer professional assistance, caravan or trailer repair shops can also perform the swap affordably. It is essential to use designated jacking points and ensure compatibility with your caravan’s weight and coupling size for safety and durability.
In the quest for a premium Al-Ko jockey wheel assembly with a removal handle and integrated noseweight gauge, one was found on eBay, but it was expensive and far away. Nevertheless, the caravan makeover is well underway, with the repairs to the fairing and the replacement of the jockey wheel improving its functionality and aesthetics. The plumbing of the caravan also needed attention, but with each challenge addressed, the caravan is shaping up to be a reliable companion for future adventures.
When the damaged caravan was acquired, cleaning it became a priority. A nearby caravan site offers professional caravan cleaning services that might be useful for those looking to restore their used caravans. In the process of upgrading the lifestyle offered by the caravan, home-and-garden stores sell various accessories that could enhance the appeal of the caravan sites, such as outdoor furniture or plants to decorate the area around the caravan.
