Awning fabric replacement

[plab]

This two-piece design is honestly quite poor, especially since the glue tends to disintegrate under sunlight. I’ve had to repair mine twice. Each time, I laid the awning flat on the ground and used strong PVC repair tape on both sides of the joint where the two pieces connect. The first time, only a one-meter section came apart. If I had known better, I would have reinforced the entire seam from the start—because a few years later, the rest of the joint came unglued as well.

 

[gt_63]

Hi all
We had the same problem last May - split along the seam. After much consideration and research (mainly this website ) I decided to just replace
We have a local campervan converter who managed to source a single sheet (grey) from The for £285 and after a couple of hours of labour we rolled away with (hopefully) a canopy that will not let us down again
If anyone needs details of the chap who helped do drop me a line. We are based on the A48 side of the River Severn on the edge of the Forest of Dean
Happy camping

 

[Prez]

Our six year old awning started to split across the join during a warm morning of 29c in the South of France recently.
We removed the fabric (a relatively simple job needing just one screwdriver) and had it sewn the length of the seam by a sailmaker which temporarily solved the problem.
The Thule agent, Rose awnings have just quoted me £392 for a replacement single-piece fabric (without fitting which would be extra).
Has anyone managed to replace the fabric (with a single piece) more cheaply?

Hi. Just replaced ours same thing happened in France last year, bought new one from club shop & fitted it myself very easy needs two of you about 20mins done.all in one piece now happy camping

 

[Benharries13!]

My original awning on my T5.1 split in at the seam during a heatwave (and freak storm) on a trip to France. Having read the thread it sounds like this is a design fault from cali's of a certain era.

After much research and weighing up the options I bought a Thule original (one piece) from the club shop. Not cheap but the most convenient option as limited on time before the next trip. It's now fitted and good to go.
I took the cassette off the van which in hind site I didn't need to do and caused an amount of ball ache fitting it back on. To access the hex bolts that hold it to the van I had to move the arm brackets. This then threw out all the positions and made reinstalling, with only 2 people, hard work. It's done now and lessons learnt. Hopefully there wont be a next time. moral of the story - always read the forum threads first!
Final word - The VW Cali forum is and has been the most incredible source of information and advice out there. Bravo

 

[Dorset camper]

Success! We have managed to replace our awning on our 2016 Cali with fabric from the shop. I have collated the tips from this thread into 1 place, but feel free to add or amend it as necessary. I will also send a copy to Shayne in the shop.


Tips:
Take a photo at each stage to help with re-assembling
If the supporting struts keep interfering with the stability , tie a rope between the “elbows”
With a permanent pen, mark the position of the fabric on the aluminium rail, so the new fabric can be positioned correctly
Some bolts can be very tight - a ratchet spanner may be helpful


To Remove Awning from Van:
It is possible to keep the awning on the van if space is limited
2 people are needed as the awning is heavy
Unwind the awning. Remove the 2 bolts that attach it to the van. Lift the whole housing UP. Mark the position of the bolts to help with replacement.

To replace fabric
1. Remove the black plastic end cap from main housing on the opposite end to winder handle (1 screw)
2. Remove the cream coloured plastic moulding (3 x screws). Notice the 2 black “washers” on each side of the moulding which the square aluminium rod goes through.
3. Remove the 2 black plastic end caps from the corresponding end of the wind-out rail (2 screws).
4. Remove 2 x small screws on the wind out rail which retain the fabric (having marked the position of the material)
5. Slide the awning out of the housing. On the van side of the awning the aluminium tube comes out with the fabric.
6. Remove 2 x small screws on the aluminium tube which retain the fabric, having marked the position of the material with a permanent pen
7. Remove the fabric from the aluminium tube.
8. Slide the new fabric into the Kador channel on the aluminium tube
9. Replace the 2 x small screws to secure the fabric to the aluminium tube.
10. Start to slide the replacement fabric into the Kador channel in the wind-out rail
11. Slide the aluminium tube back into the awning, and the front edge of fabric into Kador channel in the wind-out rail at the same time
12. Locate the square end of the aluminium tube rod into the corresponding square hole at the winder end of the tube (This can be tricky, and you may need to remove the black plastic end cap at the winder end to see what you are doing). A small rope wound twice round the roller may help to lift and turn it. This is a 2 person job.
13. Replace the cream coloured plastic moulding on the aluminium tube (3 screws) with the “washers” in the correct place.
14. Replace the 2 x small screws to secure the fabric on the wind-out rail in the correct position
15. Replace the black plastic end caps.
16. Put the awning back on the van.

We thought we had put the fabric on the aluminium tube in the wrong way, as it refused to wind in, but it was fine when we wound it the opposite way.

 

[stephen watson]

Such great instructions in this thread, thank you. As well as replacing the awning material I would add that sewing the 2 lengths together with a domestic sewing machine has worked for us. I tackled this with a helpful neighbour in our garden. Obviously you need to remove the fabric first, which I did using the instructions in this thread. By rolling up the short side it was easy to get through the machine. I did it before the glue had come unstuck the whole length. We were worried the glue would interfere with the needle, but managed ok.

 

[Perfectos]

Any photos that would assist others in future ?

 

[Pazz]

Hi all. Firstly, thank you for the excellent instructions provided within this, and all the other threads!
I too have just suffered the same in Brittany, only 25° but the full length came apart.
I've a 2014 Beach with extended warranty with VW - and predictably the awning is not covered, as not "mechanical"

To complement the instructions within this thread, there is also an excellent teardown within this thread: https://vwcaliforniaclub.com/threads/awning-seam-split-how-to-diy-fix.58845/

I managed to Gorilla Tape the seam for a temporary fix, just to get the fabric back on the roll, but it wasn't fun as the heat just made the tape wilt.

I looked at several options: new canvas now £349.99, Stormsure or Polymarine glue (these have been known to fail in heat) or an Atwools replacement fabric, and have someone stitch on the relevant kadors.

But in the end I contacted a local sailmaker for advice. He had a wealth of knowledge and has been in the industry for years. He even used to use the same PVC weld years ago, but lost faith in it.

In conclusion:
I dropped of the fabric on Weds and collected on Friday. He'd double stitched it with a membrane in-between for water resistance, and it looks great.
Total cost: £80

And he's happy to undertake similar repairs, so here's his details: https://garlandsails.co.uk/contact.html
Based in Bristol