Campervan Boiler System Pipe Repair

A leaking copper pipe in a camper van boiler system undergoes repair using a SylWrap Repair Kit

Case Study: Repair of a Cracked Copper Pipe in a Campervan Boiler System

A campervan owner makes a DIY repair to a deep crack in a copper pipe connected to the van’s boiler system. Despite the leak area being difficult to access, it was sealed in under 30 minutes to ensure the vehicle had a safe and continued supply of heating and hot water at a fraction of the cost of replacing the pipe.

Case Study Overview

Site Campervan
Location United Kingdom
Repair Type Leak repair
Defect Crack in copper pipe connected to boiler system

Repair Products

Superfast Copper Epoxy Putty, SylWrap HD Pipe Repair Bandage,
SylWrap Standard Pipe Repair Kit

Case Study PDF

Download Campervan Copper Pipe Repair Case Study PDF

Case Study Details

The boiler system provided heat and hot water to the campervan. A deep crack appeared in a copper pipe located underneath the cover of the boiler, causing a pressurised jet of water to spray out whenever the boiler was turned on.

Problematically, the crack was located at a point where the pipe angled towards the back casing of the boiler. It faced towards the side of the casing with access extremely limited.

*A jet of water escaped the copper pipe whenever the boiler was put into operation*

The confined space meant there was no room to fit a pipe repair clamp, nor apply Wrap & Seal Pipe Burst Tape with enough stretch for it to self-amalgamate effectively.

Because the boiler could be turned off, Sylmasta recommended to the campervan owner that they use Superfast Copper Epoxy Putty Stick to plug the crack in the pipe.

Superfast Copper comes in an easy-to-use, pre-measured 114g epoxy putty stick. It has a work time of around five minutes, enabling rapid repairs to be made to copper and other non-ferrous metals.

*Superfast Copper applied to the crack in the pipe*

Superfast Copper Epoxy Putty being applied in the repair of a leaking pipe in a camper van boiler system — *Superfast Copper applied to the crack in the pipe*

Before application began, the pipe was cleaned and dried to aid the adhesion of the putty to the metalwork. The required amount of putty was cut from the stick and kneaded by hand until it turned a uniform copper colour with no streaks.

Whilst soft, the putty was pushed into the crack in the copper pipe. It quickly hardened, sealing the hole. Enough putty was used to cover the section of pipe both above and below the crack to improve the chances of success by creating a totally watertight seal.

The entire section of pipe was then reinforced by applying a SylWrap HD Pipe Repair Bandage. SylWrap HD is a composite repair wrap with a water activated resin which sets rock hard in minutes to provide an impact resistant layer of protection.

Superfast Copper Epoxy Putty applied to a pinhole leak in a camper van boiler system pipe — *Superfast Copper and SylWrap HD successfully sealed the crack*

Completed repair of a leaking copper pipe in a camper van boiler system — *Superfast Copper and SylWrap HD successfully sealed the crack*

Typically, SylWrap HD would be wrapped tightly around the pipe. The space constraints meant that this could not be done effectively in this particular application, and so the bandage was cable tied to the pipe whilst it cured.

Once the copper pipe repair was completed, the boiler was turned back on. Water was no longer escaping from the crack, denoting a successful repair and saving a considerable amount of money for the campervan owner compared to the cost of replacing the pipe.