Electrolysis on new RV

[raztec]

I purchased a new truck camper recently and after only three weeks of use, I see evidence of electrolysis on one of the outside aluminum panels.

The dealer has said he will contact the manufacturer to see if it will be covered by warranty. I'm presuming it will, but am worried that this is only the tip of the iceberg.

A few questions for you guys:

1. Am a right to be concerned that if they fix this problem, it could surface elsewhere? If not in a years time, perhaps in 2 or 3 years when it's out of warranty?

2. What would cause this electrolysis and how can it be prevented?

3. What are my options in dealing with the RV dealer that I purchased it from? Ask for a full refund? Get another camper? Get them to fix the one affected area and pray it doesn't happen again?

Thanks for any advice,
R

[RV Wizard]

Hello and . We are glad to have you join us here and we look forward to reading of your adventures and experiences. I am sure you will enjoy the website and forums. Good luck. stay safe and keep us posted.
Electrolysis can be caused by several things. dissimilar metals in contact with each other, electrical backfeeds and chemical reactions. Do some home work as to how the camper is constructed since the skin is metal, (probably aluminum) make certain that fasteners are at least well coated to prevent electrolysis.

[Shadowcatche]

I will second RV Wizard! We have an all aluminum frame trailer and I monitor the fasteners going into the frame some of which are stainless steel others i.e. bolts holding axle are gold anodized grade 8. More information, exactly what is having a problem and where do you live, next to an ocean...

[Gary RVRoamer]

I would check for voltage between the frame/skin and earth ground. Even a small "leak" between hot and earth ground can cause rapid electrolysis. One quick check is to plug the RV into a GFCI outlet and see if the GFCI trips. Few 50A or 30A outlets are GFCI protected, but most outdoor 15A & 20A outlets are (required by electrical code for many years now).

[raztec]

I live near the Ocean. The camper is brand new. Went on a two week trip but it rained like crazy. Next thing I know this happened.

[Mr_D]

Originally Posted by raztec

I live near the Ocean. The camper is brand new. Went on a two week trip but it rained like crazy. Next thing I know this happened.

That looks like water damage from an improperly installed/sealed romex wire not electrolysis. If the dealer or you installed that wire I don't see how the manufacturer would be responsible.

[raztec]

Originally Posted by Mr_D

That looks like water damage from an improperly installed/sealed romex wire not electrolysis. If the dealer or you installed that wire I don't see how the manufacturer would be responsible.

Thanks for your input. What makes you think it's water damage?

The dealer says it's electrolysis. The bubbling is on the surface of an aluminum panel. They've checked for water leaks and found none.

As an addendum: The manufacturer has denied the warranty claim. However, the dealer has accepted that this is a defect of some sort and will fix the problem at their cost. I will keep you guys posted on the progress. They've yet to determine the cause of the problem.

[myredracer]

Was that Romex actually installed by the factory? If that's for 120 volts, it should have physical protection because it is exposed. If the wire just pokes through from the exterior to interior, how is it protected inside - will the insulation wear through, or is it adequately protected? I don't like the looks of that myself. What if the Romex jacket has worn through and the ground wire or neutral is in contact with the aluminum exterior? Add salt in the air from being near the ocean and you have a good recipe for electrolysis.

Odd that the electrolysis is near where the Romex is. If there is something causing electrolysis, I think you'd expect to find it elsewhere too. I'd be looking very closely everywhere just in case. If the peeling paint/electrolysis is localized to where the Romex is, I would say the two are related.

Usually when aluminum and steel are together or in close proximity, it's the steel that gets attacked. I had an early 60s sports car once with a steel chassis and aluminum body. I bought it for restoration and when I got it, most of the steel chassis was eaten away but the aluminum body was fine. To see peeling paint like that, I think you have something else going on besides electrolysis. Think of all the trailers out there with aluminum exteriors, including all the old vintage ones. You don't see them with the aluminum all eaten away.

If anyone does find the cause, it would be interesting to know what it was.

Why not just install a zinc sacrificial anode like on a boat and forget about it?

[Steve N Sal]

My biggest question would be, is why is that piece of romex or UF cable even sticking out of the camper?? In looking at those pictures it appears that someone had been digging at the molding in that location. It sure doesn't look like anything a factory would let out the door looking like that. Keep us informed and good luck, I hope they get it figured out for you.

By the way Welcome to the forum!

[spritz]

I can't believe that it would rust thru a hole in just 2 weeks. JMO
I agree with the romax wire hanging thru. I would never put it on the truck looking like that or a dealer letting it off his lot.
Puzzled

[raztec]

Originally Posted by spritz

I can't believe that it would rust thru a hole in just 2 weeks. JMO
I agree with the romax wire hanging thru. I would never put it on the truck looking like that or a dealer letting it off his lot.
Puzzled

That's the cable for the electric jack. It's factory installed apparently.

The manufacturer says it's likely water damage caused by a leak from the outside due to improperly maintained seals, which is the dealer's responsibility. That's why they've denied the warranty claim.

However, that still doesn't adequately explain the speed at which this damage occurred - a mere 2-3 weeks! That's why I'm thinking it might be an electric short as well.

[BFlinn181]

Originally Posted by myredracer

Was that Romex actually installed by the factory? If that's for 120 volts, it should have physical protection because it is exposed. If the wire just pokes through from the exterior to interior, how is it protected inside - will the insulation wear through, or is it adequately protected? I don't like the looks of that myself. What if the Romex jacket has worn through and the ground wire or neutral is in contact with the aluminum exterior? Add salt in the air from being near the ocean and you have a good recipe for electrolysis.


Why not just install a zinc sacrificial anode like on a boat and forget about it?

You're correct, electric current, dissimilar metals, salt water or deposits, they do make a perfect recipe for electrolysis. I'd use a multimeter to try and find a small current flow in the metal panels in that area. It could be a grounding issue with the skin serving as a ground path instead of a dedicated grounding wire between the camper and the truck.

I used to change out zincs on boats as a teenager for gas money. They work because the zinc is more electrically active than brass or bronze props, rudders, shafts and other metals in contact with the water. The camper isn't immersed in water (I hope) so putting a zinc on would not cause it to conduct zinc ions away in place of the aluminum.

[TXiceman]

I would be highly suspicious of that corner having been hit and a half-a-- repair was done. It certainly does not look professional.

Ken

[jesilvas]

Originally Posted by TXiceman

I would be highly suspicious of that corner having been hit and a half-a-- repair was done. It certainly does not look professional.

Ken

I agree, that looks like damage and repair.