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Following a week in Cornwall we set off on our 7hr journey home last night........about 45 mins in we lost all power to the trailer. Found the appropriate fuse in one of the car's fuse boxes and replaced it. Indicators worked fine but when side lights / headlights turned on the fuse blew again. No more spare fuses so had to call breakdown people. Not happy (2 young kids hungry & tired with us). After investigation by the auto electrics guy we found several examples of poor workmanship which led to the problem...

1. Weather proof box under the trailer in which the electrical terminations are housed was full of rain water due to over-sized cable entry holes which were left unsealed (why fit a weather proof box then savage 2 or 3 great holes in the side and leave open to ingress of water??)

2. The rectangular plug and socket leads which connect the trailer electrics together were not properly engaged - maybe with hindsight I should have checked this myself before leaving, but surely there should be some sort of clip to hold it together? Also, again, not properly sealed so full of water

3. After dismantling the rear lights on the trailer one of the spade crimps which supplies the brake lights had come free from its connection and was touching earthed metalwork - re-crimping and connecting sorted this, but as it had caused a relay in the car's electrics to fuse in the "on" position we had to drive home in the dark with the brake lights permanently on - not ideal (also, will have to have no-doubt costly repair to car electrics done now).

Has anyone else had any problems of this nature. Bit annoying when you spend 5K+ on a brand new unit, sold largely on build quality etc...

Rant over.

Danny I too have an Olympee (second hand) and although all the trailer electrics are working fine I also found the same IP rated junction box with gaping holes and hence water in it and so replaced it. The twist on connectors were also not the best. Rarely used in blighty but elsewhere quite common. I think the thought is that it is only 12V and little used cos it is not as though brake lights are saftey critical or anything.

The plug and socket to the kitchen (trailer board) is also not realy fit for purpose as it is not water proof. On mine an attempt has been made to weather proof it by applying glued heatshink to the rear of the connector and cable but that does not stop water entering from the front especially as it is right in the path of wheels and hence spray. But hey what is the chance of rain in blighty? I have considered changing this for some other connector type that is also easier to connect and disconnect but for now the application of some grease has kept the water at bay.

So it sounds as though the problem was with the light cluster. The quality of 12V electrics is pretty poor even in modern day cars which still use pressed galvanised steel for the light clusers. Also the fusing of loads can be very poorly implemented with small loads sharing circuits with large loads etc. It is bad really but very common.

I have seen it on many a generic trailer board especially if the light cluster has been knocked or the lens damaged. I have even seen them melt simply from the heat of the lamp.