Apologies if this has already been addressed in past forums, my problem is a case of corrosion from which seems to be from the inside of the gas locker door, I have an Eriba Troll 550 (2012), I noticed this corrosion around the handle this year, it looked like fungi from the inside but on further inspection it is corrosion, the outer skin is particularly bad and this has happened over a period of one year, has anyone else experienced this, the rest of the van is in excellent condition apart from this locker, I've owned different makes of caravans over the years and never had an issue like this, I certainly wouldn't expect it on a relatively new van, it seems I have three options, 1 contact the manufacturers (expect nothing there), 2 re-skin the door or source secondhand, 3 dig into saving and purchase new replacement (guessing will be expensive),any help would be much appreciated

We had exactly the same problem with our 2012 Troll 550 a couple of years ago. Jandi quoted nearly £1000 for a new door so I decided to see if I could repair it myself. What you see is just the tip of the iceberg!
Dismantling the door is not easy without damaging the frame but it is possible with care and patience.
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This is what It looked like after disassembly!
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You will need to purchase a sheet of aluminium of the correct thickness. I can't remember the exact thickness but it's around 0.8 mm thick.
Also some 3mm marine ply and some offcuts of 18mm marine ply to make up the inner sandwich. The polystyrene layer was still intact on ours so this was left well alone. But if your corrosion is on both sides of the door then you will probably need that too.
The 3mm plywood will need soaking in water to bend to the correct shape and then clamp in shape till dry.
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Use the old aluminium panels as templates for cutting you new sheets.
I took the old panel to a paint factors for colour matching and had a aerosol mixed.
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I sealed the new panels with plenty of sikaflex when resembling to stop this happening again.
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The finished repaired door looks as good as new and cost around £50 to repair.

Excellent work and result Martin.

Many thanks for this info, I also got a quote for £1000 and will not pay it, certainly for something that has an inherent fault in the manufacture, I have the winter to do exactly what you have done.

Regards

Shaun

For some reason it only seems to effect 2012 models. Must be a sealing issue that was different on other years.
Jandi did contact Hymer as it is a design or build issue but they were not interested.

Good luck with the rebuild.

Apologies for resurrecting an old post, but I'm looking to sort some corrosion on my own gas locker door. Can anyone advise on how the metal frame is removed from around the door, is it held on with glue? There are no obvious fixings.

I took the door from my 2007 Triton apart a couple of years ago.
As I recall,the frame is in two parts, secured in place by screws. The screws are revealed by removing the "furry" seal.

I removed the lacquer with acetone, buffed up the aluminium as best I could and then resealed it with an external lacquer applied with a rattle can aerosol.

Prompted by this I just checked the bottom of the gas locker door on my recently acquired 04 540. No drain holes and it feels like the wood has gone about 1" up from the bottom. Not too happy having just shelled out the thick end of a lot of dosh to LF for it....

I will be - only found it this morning. Fiddling around in the gas locker I remembered this thread and thought - oh good mine is not a 2012 model but I'll just check for drain holes...none. Then I gave the ally a bit of a squeeze.....