Tab 320S A/C Leak

dhauf

Just wanted to post this since summer is here and many are running their A/C units more frequently.  While converting my battery system and converter over to a lithium power center, I had my A/C running for an extended time while working inside the camper.  As I was working in the electrical area, I noticed water pooling up between the wall cavity between the shower area and the electrical right behind the solar controller.  I did find the water leak after removing the mirror in the shower and looking though the access hole and found a crack in the flimsy A/C condensate tray.  This is now the second time this cheap plastic has developed a crack.  I know I have read a ton on having the trailer pitched down slightly etc since that's where the drain is and it is true, you do need a slight pitch to drain better, but for those having leaking issues with water getting all over the seating area or leaking behind the wall make sure you check that tray.  I am bewildered why Nucamp would use such a flimsy piece of material as a condensate tray.  They welded this nice frame in there and they could have easily made the tray stainless steel.  Anyway I have modified my tray to never leak again.  I used clear flex shot in a can to seal the perimeter of the aluminum frame to the bottom plastic pan, and I glued the cracks and also reinforced the broken corner that goes in the wall with Flex tape.  It is working perfect now and should be stronger than it was.  My next step is to develop a 3d printed insert that will attach to the factory tray and drain.  For now I am sure this will probably never leak again.  I just figured I would post this since many may be chasing there tails tryin to figure out the leak.  Here are some pictures of the cracks as well as the repair.  I used gorilla glue to seal the cracks as it is flexible.  I hope this can potentially help someone else with a similar issue.

BrianZ

Thanks for posting this, @dhauf.
Which corner is in the first photo?  And if there was a crack there like the one on the 2nd photo, how could you possibly find it? (Looking from the inside after removing the ac unit, it would be hidden by the aluminum framing, and outside it's hidden by the wood cabinet.)
Regardless, I guess if you caulked all around the top & bottom of the aluminum frame that's inside the bottom of the tray, then that should seal against any leaks at the corners, right?
I had some leaking that I wasn't sure was due to poor leveling, but only at the rear near the window.

dhauf

@BrianZ sure figured it might save some headaches for someone in the future.  So the crack in the first picture is on the left front corner as you are facing the A/C unit.  I noticed the seating all wet, now I know these units are not the best at removing moisture and sometimes they can sweat in high humidity but this was an abnormal amount dripping out.  I also have my camper pitched forward as recommended always and it still leaked on me.  Funny you ask how I found the other in the wall.  So I had been upgrading the electrical panel in camper to allow for charging two new 100ah lithium batteries I was installing under the passenger side seating area.  Since I had the power shut off and it was extremely hot inside the camper I had cracked that side window open and ran an extension cord to run the A/C unit. As I was working in the electrical area I started noticing water pooling up against the shower wall under the solar controller.  I had previously sealed all the other corners but not the piece that was going into the wall.  So I had to kind of hunt down the source.  I first removed the panel behind the shower pipes and noticed the plywood was a bit damp but could not see a drip.  The next thing I did was remove the TV mount and plastic behind that to take a look.  That when I saw the drip, I noticed a cut out from there behind the shower mirror, so I had to carefully pull of the mirror.  There are 4 screws with brackets holding it and then some very sticky stuff all around the hole.  Once I removed the mirror I found the crack.  I used flex shot in a can from Lowe’s to seal all around the aluminum frame rails, I also shot some in each of the welded seams since these aren’t solid welds, but rather tack welds.  I spread everything around with my fingers and allowed to dry for 24hrs.  I also used white flex tape the tape over the extended price through the shower to reinforce it.  So far I’ve now been using it the last 4 days with no leaks.  I left everything open just to make sure.  So far so good and I don’t think it will ever leak again.  If you do this just make sure you are very liberal with the flex shot and get in every corner. If you looking for the leak remove the A/C unit first and then use a very bright light inside the cavity, then look all around the bottom and you’ll see where a potential crack might be.  It might not be a super common issue I don’t know, but on my 2018 and 2019 T@b’s both developed cracks after a couple trips in.  Anyway I hope this helps and if you have any other questions feel free to let me know.  One thing I also used before the flex shot was gorilla glue and I drizzled it all around the top of the aluminum frame and let it soak to the bottom and dry 24hrs first, then I followed this up with flex shot the next day. 

rcarlson1957

dhauf. Found the exact same thing this week in addition to drain not draining well. It's been getting hot here in Texas and had A/C running while plugged into garage power and you get plenty of condensation on ground via the A/C drain. A day later was just as hot and didn't notice any. Looked in shower and could see little bit of water dripping from below mirror. Took mirror off and sure enough, not only had the same crack as shown but also drain had become clogged and pan was full. Took some wire and snaked it down drain and drained quickly. Poured some disinfectant down it too. Let it dry out in the heat and today is flex seal and flex tape day. Will also put a few of those A/C tablets in it. The other thing that would be nice is if there was an easy way to clean the A/C drain without taking mirror off or pulling window unit out. Thanks for the post!

mytabbys701

yep - just pulled my mirror, and sure enough crack just like the one shown by @dhauf -- off to get flex tape and flex shot, thanks for the info

gulfarea

Is there any way that plastic drip pan can be removed so I can seal it with fiberglass and epoxy? Art

dhauf

Unfortunately no good way of removing it unless you break down the wood frame around it.  There is also an aluminum structure inside to contend with as well.  Wish they would have put in a metal drip tray instead of cheap plastic.  I thought about constructing one and putting it inside the metal frame.  Once I sealed mine though with flex shot and flex tape it has yet to leak again.  So I do think it will hold up for quite a long time.  There is one small weep hole drilled underneath the AC unit so it can be entirely possible to fabricate a metal tray to go inside under the AC and drain out the tube instead.  

gulfarea

dhauf Thanks so much for your reply. They could have cut up a small used plastic milk jug and it would have held up better! Art