MMM - 1996 Article

"A motorcaravan normally represents a major long-term investment, which can rapidly be reduced in value by the effects of corrosion. However, as Kim Henson explains, help is at hand..."
.Motorcaravan Motorhome Monthly: Article ~ November 1996
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Rustbusters

As with any motor vehicle, corrosion on a motorcaravan can take its toll, reducing sound metal to crumbly dust, in the process wiping years off the life expectancy, and knocking pounds off the value. Essentially, what happens is that if air and water are allowed to reach unprotected steel, chemical reaction takes place, reducing the sound metal to iron oxide, which decreases its strength and destroys the affected structure. The presence of industrial fallout' in the atmosphere, also salt and other contaminants picked up from the road surface, accelerate the process.

The steel chassis frames on motor-caravans can be seriously affected, as can, of course, the steel structure employed around the cab, also the front outer wings, inner wings and panelwork, as well as the sills and brake pipes. In fact, any exposed steel will rust and the first signs of flaking, bubbling paintwork can become apparent remarkably quickly!

 
 

The aluminium chassis structures used on some motorcaravans are not immune either, with sound, bright metal soon turning powdery unless adequately protected.

Of course, compared with cars, motor-caravans are often at greater risk of attack by the elements, to the extent that they usually have to live' outside (being simply too tall for most domestic garages), and many have to spend their time parked on damp grass, which also does little for their long-term survival prospects. This is all rather sad it you have sunk several (and often many!) thousands of pounds into a vehicle you hope will last 'indefinitely'

Enter Rust Busters! Fortunately, you needn't watch your pride and joy 'dissolve' before your very eyes, and the cost is comparatively low, compared with putting to rights the extensive structural havoc which can be wreaked by rampant corrosion. I recently visited a Dorset-based firm who are well aware of the problems which can beset unprotected vehicles, and have made it their business to add years of working life to a range of vehicles, from cars (including classics) to in particular motorcaravans.

To protect vehicles for a long-term future, 'Rustbusters' (who operate near Bournemouth) use Finnigan's Waxoyl products which have been proven in service over many years. These are applied by special high-pressure spray equipment which has been specifically developed for the job by Philip Lewis of Rustbusters.

Waxoyl is a wax/oil-based product designed to chase Out moisture and coat the surfaces of unprotected metal, and to creep' into all joints, to give lasting protection. Available in 'clear' (beige) or black colours, it semi-dries to leave a tough, flexible and weatherproof film, to protect metal for years. For areas exposed to bombardment from stones, grit and so on, Underbody Seal with added Waxoyl is used. This gives comprehensive protection, providing an even tougher coating, designed to keep the elements at bay.

Although, ideally, it is best to treat a vehicle when young, it is still worth having older motorcaravans protected. The treatment should at the very least help to prevent any light corrosion already present from becoming more serious. Emphasising this point, it is interesting that Waxoyl is used extensively by enthusiasts of classic cars, to help keep them on the road well past their original 'allotted' life span.

It is also worth noting that even if your vehicle received factory anti-rust treatment, additional protection is worthwhile, especially as the vehicle ages.

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The Process

Of course, Waxoyl products can be applied by do-it-yourself methods, but many owners prefer to have the work carried out by someone else. In addition, one of the benefits of the Rustbusters system is that the equipment they use has been specifically developed to ensure high-pressure coverage of all sections of the vehicle, and I can confirm from personal experience that this is not so easy to achieve using a hand-operated pump or relatively low-pressure spray equipment.

On arrival at Rustbusters' premises, the motorcaravan is driven over a purpose-built, seven-metre-long inspection pit, to give ready access to the whole of the underside of the vehicle. Before any anti-rust products are applied to the wheel arches, or near the exhaust system, protective covers are fitted to the wheels, brake discs and exhaust pipe(s). (The air suspension units, if fitted, are also protected.) In addition, heavy deposits of dirt, also moisture, are removed from the underbody, using a heavy-duty extractor system and high pressure air blast gun.

 
 

Both Waxoyl and Underbody Seal with added Waxoyl are applied by the high-pressure spray equipment, through a fascinating variety of purpose-designed lances, extension tubes and nozzles. These give a range of spray patterns (including 'fan' sprays for wide coverage on exposed metal, and 360 degree types, for treating internal surfaces of box sections).

Prior to application, the products are maintained at a stable temperature within thermally-insulated containers, to ensure optimum fluidity and coverage of all nooks and crannies within the vehicle's structure.

Each vehicle is systematically treated from 'stem to stern', with all vulnerable areas receiving comprehensive attention. So the longitudinal chassis beams, as well as all the cross-members, are treated internally (normally through existing access apertures), then the external faces are coated (including plywood floors, on coachbuilt and A-class motorcaravans). Rustbusters take a great deal of trouble to ensure that all the structure is treated in this way, including the oft-neglected 'hidden' sections.

The vehicle is raised from the ground for attention to the wheel arches, which are fully-coated with the abrasion-resisting Underbody Seal with added Waxoyl. This is a thicker compound than Waxoyl alone, to withstand the pounding received by metal within the wheel arches and similarly vulnerable areas.

The hollow sections between the inner and outer front wings (incorporating the 'at risk' wheel arch lips) receive special attention, with Waxoyl being introduced from within the engine compartment, also from the open rear ends of these areas, which are normally accessible only from under the vehicle.

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Doors & Bonnet

The door frames and outer panelwork need protection, too, and Rustbusters make a point of ensuring that all sections of each door receive full coverage, by introducing Waxoyl to the upper section of the frame, also the centre area (including the moisture-trapping ledges under each window) and the lower edge. Where, as is sometimes the case, additional apertures need to be made in the structure to provide access for the injection probes, the edges of the holes are coated in Waxoyl and, on completion, tightly-fitting grommets are then used to seal them.

The hollow reinforcing beams in the bonnet can also harbour moisture, and here, as elsewhere on the vehicle, Waxoyl is pumped into each strengthener in turn, to penetrate into all the seams and ensure that rust cannot get a grip. All hollow box sections around the engine bay also receive similar attention, as do the panels behind the grille/in front of the radiator, and the front cross-member, plus the inside of the front valance. Rust is often found here, on unprotected vehicles.

 
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Conclusions

The elimination/prevention of rust in the manner described can cost a few hundred pounds, but in relation to the price of a replacement motorcaravan, the outlay is relatively low, and will help to ensure that your vehicle looks better and lasts longer, and is therefore more likely to retain a reasonable resale value. You will also have the peace of mind of knowing that the vital underbody structure should be far more capable of lasting for a 'lifetime' than if left in its natural state.

Rustbusters provide a comprehensive, friendly service to the owners of all motor-caravans. Most vehicles can be fully treated in a day, with precise cost dependent on the size of the vehicle.

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Step One
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The problem: Without protection, your vehicle can - surprising quickly - suffer from rust damage like this. It 'disolves' the bodywork and eats its way into the chassis, reducing sound metal to crumbly oxides.
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Step Two
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The product: Rusbusters use well-proven anti-rust products by Finnigan's, including the famous Waxoyl (clear and black), plus, for areas prone to abrasion from stones etc, Underbody Seal with Waxoyl.
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Step Three
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The equipment: Thermally-insulated containers keep the anti-rust products at a stable temperature, ensuring a viscosity ideal for spraying through Rustbusters' specially-developed high pressure equipment.
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Step Four
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Before any under-wing areas are tackled, the wheels, tyres and brakes are protected from over-spray by being covered with plastic sheeting. This ensures that the anti-rust products reach only those areas intended!
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Step Five
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Similarly, the exhaust system is allowed to cool, and is the wrapped in plastic, to prevent overspray from covering the pipework. Waxoyl is an excellent product, but is not intended for coating very hot surfaces.
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Step Six
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Prior to application of the Waxoyl-based products, heavy deposits of mud and moisture are cleaned from the underbody/under wing areas by use of a stiff brush and heavy-duty extraction system.
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Step Seven
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Rust often takes hold in the vicinity of the rear axle beam. Rustbusters coat the entire are with Waxoyl. They have a wide range of nozzles through which the products are applied, including a 'fan' spray jet.
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Step Eight
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The longitudinal chassis beams, also the hollow supports often employed for mounting the rear springs, require full protection. A long extention probe is fed into each aperture, to apply a 360 degree spray.

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Step Nine
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Chassis cross-members are particulary deep on some motorcarvans, but these present no problems to Rustbusters. Waxoyl is introduced to all internal cavities through the existing apertures in the beams.
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Step Ten
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The front and rear faces of each cross-member need to be fully coated, in addition to the internal structure. Here, black Waxoyl is being applied to a Fiat's chassis, by means of a special wide-angle fan spray.
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Step Eleven
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Sill members are especially prone to corrosion, and need to be coated inside and out. Rustbusters apply Waxoyl under high pressure to the insides of the sills, ensuring that all corners are fully treated.
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Step Twelve
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The exposed faces of the inner sill walls (especially vulnerable just behind each front wheel) are coated with black Waxoyl to complete the protection of these areas. The product 'creeps' into all crevices.
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Step Thirteen
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Sometimes it is necessary to drill additional holes in the structure (for example, in the front doors), to ensure that all internal surfaces can be reached by Waxoyl. Extra apertures are kept to a minimum.
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Step Fourteen
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The steel-preserving product is injected under pressure to coat all internal surfaces of the doors. The upper frames, centre and lower sections all receive individual full treatment, in turn.
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Step Fithteen
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Where it has been necessary to drill additional access holes, the raw edges of the apertures are treated with Waxoyl, then the holes are selaed using purpose-designed, snug-fitting, neat plastic grommets.
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Step Sixteen
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The inner facess of the front outer wing and wheel arches are fully coated from inside the engine bay, and (in some cases) from beneath the rear end of the front wheel arch, on each side. Coverage is comprehensive.
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Step Seventeen
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The bonnet often incorprates hollow strengthening beams, in which rust can get a grip, unless deterred. Narrow probes ensure that the Waxoyl reaches all internal surfaces within these double skinned areas.
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Step Eighteen
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Nothing is left to chance. Waxoyl is injected into the vulnerable areas above, below and on either side of the grille. The inside of the front valance is also treated, plus all rust-prone sections around the engine.
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