Exterior Cracked Jayco Startcaft front window awning

Jared01

Active Member
Oct 28, 2016
136
138
43
39
Sydney
Hello,

Coming back from recent camping trip, on the highway, I heard a bang, looked back and saw awning facing straight up in the air :-(

My bad as I forgot to lock it down (recently the air struts stopped holding the awning up, so I checked if it would hold up or not, which it didn't and then forgot to lock it down. Should be part of the pack up before driving off).

The 4 screws under the awning, securing the gas strut into the fibreglass were ripped out and are now threaded. I have all of the parts though.

Happened to anyone before? Did you go through insurance?

Just after some advice whether if not that bad to consider repair (but I wouldn't know how) or go through insurance (excess is $300)
 

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Drover

Well-Known Member
Nov 7, 2013
10,056
16,162
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QLD
www.expandasdownunder.com
Have a look here at Caravans Plus depending on the size the dearest is under $400; https://www.caravansplus.com.au/external/windows/shade-protector/

Easy enough to replace and not worry about insurance as they would require you to take it to a caravan repairer, more time and money while it would take 30 mins yourself.

A repair could be possible but its a high stress area so the chance of it failing again would be high. i have rebuilt the strut mount points on Big Mals' and have some small crack appearing around the hinge mounts so when they get bigger it will be replaced no sense wasting time and effort on it then.

I got new struts from https://www.gasstrutguys.com.au/ they have an ebay store as well, been buying new struts from them for 20 years I reckon, good price and they don't fail just measure and order.
 

Jaybird

Active Member
May 31, 2012
165
52
28
Gippsland Lakes
I did a similar repair to a fibreglass door on the boat I was restoring. Where the screws had pulled through I got a piece of PVA sheet and fibreglassed it over the area on the back and sprayed it, this gave strength to re screw. On the cracks I pushed them out from the inside and repaired with fibreglass from the rear. On mine there was no bits broken out and the cracks fitted back together and were hardly noticable. If there is bits missing then they will have to be filled from the front and the awning resprayed. I have used the method on a car bumper and it also worked well. Fibreglass repair kits were form bunnings.
 

BJM

Well-Known Member
Sep 29, 2018
293
289
63
Yamba
Pretty sure the front awnings are polycarbonate so polyester fibreglass repairs not suitable ,a specialised bonding glue is needed for panel to panel etc .I would contact a good plastic welder ,amazing what repairs can be done
 
Last edited:

Jared01

Active Member
Oct 28, 2016
136
138
43
39
Sydney
Thanks for the feedback and advice.

It is a shame that it happened and I will never forget to check it is locked again, after it is repaired.

Will probably go through insurance, but the awning is locked and secure for now, so will find the right time to book it in.
 

BJM

Well-Known Member
Sep 29, 2018
293
289
63
Yamba
Front polycarbonate boot lid on Jayco 16.52 outback damaged ,replacement took weeks to make ,was over $800.00 !
 
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Reactions: Drover

BJM

Well-Known Member
Sep 29, 2018
293
289
63
Yamba
They do flex alot mainly where the strut is attached in the middle .Latter ones had two struts ,one either side.
 

RickB

Member
Jul 22, 2017
66
47
18
Pakenham Upper, Vic
Three more issues ..:
1. Where the rubber bushes on the inside of the awning touch the van body it is wearing the gel coat / fibreglass away!
2. The awning is attached to the hinge with pop rivets which are cracking the awning!

189B6926-9FD8-453E-9CA8-633548DF11A2.jpeg

3. Under the awning is a plastic strip which hides the join between the two pieces of covering.
This join collects dirt and water sits in the top portion and eventually turns green.
There is also a minuscule amount of sealant which on my van has cracked and possibly letting water into the joint so I decided to fill the joint with silicone ensuring that it is higher on the van so that the water and dirt can easily run off.

Do others have these issues, if so how did you resolve them.

Thanks,

Rick.