For many Australians, the open road and a trusty caravan spell freedom, adventure, and the chance to explore our beautiful backyard at your own pace. But what happens when your home-on-wheels turns into a money pit, thanks to a hidden menace lurking beneath the surface?
That’s precisely what happened to one traveller who found himself staring down the barrel of a $6,000 repair bill after a seemingly minor leak revealed a much bigger problem: the dreaded ‘silent caravan killer’.
It all started innocently enough. Queenslander Chris Ferlazzo noticed a ‘small leak’ during a trip and, like many of us would, quickly taped it up and carried on.
But when he returned home, a visit from a caravan repairman uncovered the real culprit: a faulty J mould.
J mould is a trim that seals and protects the edges of your caravan’s exterior panels. It’s a small detail, but as Ferlazzo discovered, it can have massive consequences if not installed correctly.
‘No silicone at all,’ Ferlazzo said, describing what the repairman found under the J mould.
‘The whole J mould will have to come off, cleaned all surfaces, siliconed and reinstalled. This is both sides, roof, sides and bottom. I also have to remove my door as there is no silicone behind it as well.’
The quote for professional repairs was a whopping $6,000. Not one to be easily deterred, Ferlazzo decided to tackle the job himself, estimating about $600 in materials and a few days’ work.
‘Haven’t started yet,’ he admitted, but he’s determined to get it done.
The ‘silent caravan killer’ explained
So, what makes a leaky J mould so dangerous? According to Victoria-based specialist Josh Brown, it’s one of the biggest problems in the RV (Recreational Vehicle) industry.
‘We call them silent caravan killers because you don’t see water coming in through that area, but it slowly seeps into the wall cavity and then you see water damage, and by that stage the caravan’s destroyed,’ he explained.
The problem is insidious. Water sneaks in, often unnoticed, and quietly wreaks havoc inside your caravan’s walls.
When you spot the tell-tale signs—warped panels, musty smells, or visible water damage—the rot has often set in, and repairs can run into the tens of thousands.
Brown said a ‘nice underseal’ of silicone is vital in applying a J mould.
But as Ferlazzo and many other caravan owners have discovered, this crucial step is sometimes skipped entirely.
A widespread industry issue
Unfortunately, Ferlazzo’s experience is far from unique. He’s had similar issues with a previous van, though that one at least had ‘more silicone than this one’.
He’s not surprised by the repairer’s discovery. He calls it an ‘all too common’ problem and blames the industry’s lack of quality control.
‘It’s expected with the lack of quality in the industry,’ Ferlazzo said. ‘There are no legal standards in the industry. They could use no silicone anywhere, and it’s not illegal.’
This isn’t just one man’s opinion. An anonymous industry insider shared that the caravan manufacturing and sales industry is ‘extremely poorly regulated’.
Problems range from inadequate tyres and incorrect weight specifications to poor salespeople’s advice and a general focus on quantity over quality.
‘Caravans are being supplied brand new with inadequate tyres. Weights specified are often incorrectly determined. Specified minimum towball weights are often too low,’ the insider said.
‘GTM [Gross Trailer Mass] limits are sometimes incorrectly determined, and salespeople give very poor, uninformed advice, such as only considering caravan ATM [Aggregate Trailer Mass] and vehicle towing capacity. They ignore tow ball limits, axle weights and much more. I can only assume this is done in an effort to gain sales.’
What can caravan owners do?
If you own a caravan—or are thinking of buying one—how can you protect yourself from the silent caravan killer?
- Inspect regularly: Don’t wait for a leak to appear. Check your caravan’s seals, especially around the J mould, doors, and windows, at least once a year. Look for cracks, gaps, or signs of water ingress.
- Demand quality: If you’re buying new, ask the dealer about sealing. Don’t be afraid to request documentation or even a demonstration of how the J mould is installed.
- DIY maintenance: If you’re handy, consider learning to reseal your caravan—plenty of online tutorials and forums where experienced caravanners share tips and tricks.
- Push for regulation: The industry’s lack of standards concerns all caravan owners. Consider supporting consumer advocacy groups pushing for better regulation and quality control.
- Don’t ignore minor problems: Ferlazzo’s story shows that a ‘small leak’ can quickly become a big, expensive headache. Address issues as soon as they arise.
Have you had a similar experience with your caravan? Do you have tips for keeping your van watertight, or your own horror stories? We’d love to hear from you! Share your thoughts, advice, or questions in the comments below.
Also read: Caravan driver’s outback ordeal uncovers must-have life-saving item
