Jayco Discovery boot leaks

Submitted: Wednesday, Feb 26, 2014 at 09:28
ThreadID: 106428 Views:4378 Replies:5 FollowUps:2
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I noticed that after some heavy rain that the boot on our fibreglass body 2010 Discovery contained a considerable quantity of water. Inspection of the boot lid revealed that the hinge had partially parted from the boot lid allowing rain to pass through the resultant gap. The hinge is secured to the lid with split rivets, many of which had failed resulting in the troublesome gap. I drilled out all the rivets intending to replace them all, but have realised that the underlying cause of the problem is that the boot attachment face for the hinge and the attachment face on the caravan body are not parallel when the boot is in the closed position. The stainless steel hinge is very rigid in the closed position and something had to give...and that's why it tore out the rivets.
Replacing the rivets wont solve the problem, its always been there and wont go away with the original design.
My real concern is that if I don't do it properly and carefully, I could crack the fiberglass lid or the caravan body

Has anyone else had this problem and have they found a way to get around it?
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Reply By: Bobjl - Wednesday, Feb 26, 2014 at 09:55

Wednesday, Feb 26, 2014 at 09:55
I suggest you discuss the issue with Jayco. From your advice it seems to be a manufacturing defect and which the manufacturer should rectify.
I am mindful the technical warranty period has long elapsed, however if it was a manufacturing defect, it is not unreasonable that they accept responsibility.

AnswerID: 527255

Reply By: Member - nrb1748 (VIC) - Wednesday, Feb 26, 2014 at 12:34

Wednesday, Feb 26, 2014 at 12:34
Not sure if this is the same - I had a problem on a 2011 Sterling where the boot was hard to close and was 'springing'. Under warranty about 15mm was cut from the fibreglass lip on the caravan body at the top of the boot.

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AnswerID: 527260

Follow Up By: Ross M - Wednesday, Feb 26, 2014 at 15:14

Wednesday, Feb 26, 2014 at 15:14
They have all passed been by Jayco's strict, "the customer comes first", quality control process aren't they.

They looked ok from the office window as they left on the back of a truck or were towed away..
FollowupID: 809689

Follow Up By: Isuzumu - Thursday, Feb 27, 2014 at 09:56

Thursday, Feb 27, 2014 at 09:56
Read my post Ross and then say Jayco don't care.
FollowupID: 809728

Reply By: Member - Keith Q - Wednesday, Feb 26, 2014 at 20:37

Wednesday, Feb 26, 2014 at 20:37
Thanks for the replies so far. I have not contacted Jayco at this time because I was hoping that I would find some clever person who has already addressed the problem. I'm sure our issue with the lid would not be an isolated one. I will contact Jayco in due course if I don't get any joy from this excellent website.
AnswerID: 527296

Reply By: Member - Andrew L (QLD) - Wednesday, Feb 26, 2014 at 21:05

Wednesday, Feb 26, 2014 at 21:05
We are talking about the "belmont" of caravans...what do you expect.?

There's plenty more Campbellfield Victoria brands of parallel uncapability.
AnswerID: 527302

Reply By: Isuzumu - Thursday, Feb 27, 2014 at 09:54

Thursday, Feb 27, 2014 at 09:54
We have a 2011 Jayco 17.55 Sterling Outback, brought second hand when two years old. It developed a crack above the rhs window guard, I asked a Jayco dealer if they could fix it and after sending photos, vin no etc Jayco came back and said they would replace the whole front of the van at no cost to us.
So I am very happy with that.
AnswerID: 527337

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