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Delamination of the Sidewall 1

I have been meaning to get around to this for some time, autumn seemed like the best choice.There has been a previous repair in this area and it was picked up on a service we had done in September 2006. I asked if it would need immediate attention, but as it was not through water ingress, just had to keep an eye on it, and it did not get any worse. The wallboard inside has come away (the sidewalls are a bonded construction) not sure about the bond of the polystyrene to the aluminium skin, as on a trip the aluminium bowed a little in the strong sunshine (yes, we did have some).

So it is a journey of discovery, assess as I go along, then do what I think is best.

Action Plan; Clear the area to get at the wallboard, re-glue everything, put back together, job done.

Oberview
Front offside, cushions removed, the delamination is under the window and the full width of the seat.

The Curtains
1st job, is to remove the pelmet and curtains.

Window blind 
Five screws held the pelmet to the underside of the lockers. Next the window blind...

Side fixing
A single screw at the bottom of the upright holds the window blind side in place.

End cap
At the top remove the end cap, which is a push fit so a tug got it off.

Remove screw
This one had a single screw, sometimes there are more.

Blind removed
Blind removed, next, the seating has to come out, attached to the wall by...

Fixings of the seat
...four screws at the rear of the seat-back.

Fixing at the front 
The screws holding the cross pieces were then removed. The thinking behind this was, I wanted to leave the front of the cupboard in place.

Problem here
But that was not to be. The only thing stopping the seat coming out was some screws behind here from the other side.

More work 
So the front has to come out with the seating; that means these two electrical connections, 240v and 12v will have to be disconnected.

Mains power 
Switched off all power, the 240 volt supply at the fuse box. Also put the 12v switch to the off position.

Heater controls
The 240v switch for the heater (on the right). Two screws and it was a simple matter of pushing it through a slot in the ply to the rear. The brown box (on the left) is for gas operation.

Another problem
Held onto the side with two screws, but this black thing (a gas sensor or something) cannot be disconnected from the circuit board.

Gas plug
It can be disconnected here at the back of the heater. Also cut through various cable ties to release the black wire.

All disconnected
It was pulled through the front. The 12v supply was disconnected and put into a terminal block and covered with electrical tape for safe keeping.

Fixing of the front panel
Now removing some screws that held the side to the front drawers and moving the drawers to one side after removing four screws....

Seating removed
...allowed the removal of the seating, there is now a clear space to work in.

Joint cover strip
A join in the wallboard towards the front, pulled the coverstrip off, it looks a bit yucky!!

Window rubber seal
The window rubber was removed a little to aid removal of the wallboard. Marked the wallboard where there will be a new join, this should be hidden by the pelmet.

Damp meter
Wood looked stained, so out came the damp meter. Checked the whole window, it is all dry.

Bonded panel!!
After cutting the walllboard with a Stanley knife and straight edge, then running it down the side of the window it just came away.

Breaking bond
For the bottom of the window, a chisel was used to gently prise the wallboard while scoring with a Stanley knife.

Pulling off the wall
Still held fast at the floor. The only place the wallboard was stuck, was to the wood, none of the polystyrene was secure.

All off
Scoring through at floor level, it came away.

Hit and miss
A closer view of the glue on the backside of the panel. It was stuck very well to that, but not at all on the polystyrene.

Damp meter again
At the bottom mid point of the window, again staining, this time the meter showed a higher reading in one area. Suspect it could be a screw in the lower rail. Will have to take it off to investigate.

Page 2- Delamination of the sidewall

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