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We had the same problem...infact my post is about 6 pages away.  We bought a sponge from Ebay....i was absolutely devestated especially as my OH drove a 6 hr round trip to pick the van up.  He is having to replace the full wall on the side of the door.  If you need wallboards try O'Learys they are very helpful.  When OH tried to take wallboard off the polystyrene came off with it, so we are currently awaiting polystyrene to be delivered from company "down south" as needs to be 22mm and nobody local stocks that size. 

We know what you are up against.  It is heart-breaking, though if you are willing to do the work yourselves look at Wizards site.  If you have same problem with polystyrene just put a post on here and i will get site from OH.  Paying more in carriage than we are for polystyrene!!

Good luck.

Michelle

Hi Topbuzz , you should have my reply by now , here it is for others to add input if they'ed like to .

atb

Wizard


Hi Ian , the first thing to do is buy a damp meter for B&Q  and see just how
big the damp area is .
From what you've said it sounds like the main places that the water is
getting in are the window seal and door seal , but if the damp area extends
right to the top of the wall then the awning rail will need resealing too .
I wouldn't use a hose to see where the water is getting in as there's enough
in the caravan already and adding extra could make the problem worse .
The way i'd tackle the problem would be , access the size of the damp area
with a damp meter , then remove the wallboard from that area , you will then
get an idea of how long the area has been damp , ie the spars ( framework )
behind the wallboard is either rotted completely or they are sound but wet ,
and may possibility dry out .
When removing the wallboard cut the damp area away using a stanley knife ,
the wallboard is only 3mm thick , use straight lines so that when you
replace with new wallboard it is easier to just place a sheet up to the
original wallboard . To lift the damp areas of wallboard use a wallpaper
scraper and slide it between the wallboard and the polystyrene , try not to
remove large pieces of polystyrene , it will dry out with the use of a fan
heater , the polystyrene is normally bonded to the caravan skin so there
shouldn't be any water between the outer skin and the polystyrene .
Take pictures as you do the work , these will help you when you come to
rebuild , ie see how the spars were placed , how fittings go back into place
etc.
Once you have removed the damp wood ( wallboard / spars ) dry the area using
a fan heater ( don't leave unattended or place too close , risk of fire ) ,
have some way of letting the moisture out either a window open or a roof
light ( remember to shut them when you've finished drying out that day ) .
Try to protect the area from rain , ie a plastic sheet taped on the outside
of the caravan from the roof down , gaffer tape could be used .
So now you have the area dried out and protected the next step is to reseal
, this is done in different ways depending where you are resealing .
If you are doing a window seal the wallboard will need to be back in place
before refitting a new seal ( or resealing a old one ) .
If you are resealing a awning rail it will depend on if you have had to
remove any of the spars that the rail screws into , if the spars were ok
then you just unscrew the awning rail , remove it , reseal and refit ( see
my website instructions ) . If you have removed some of the spars then ,
remove the awning rail , refit the new spars in place then refit the awning
rail .
I haven't resealed a door frame myself , so can only assume that it's along
the same lines as a awning rail reseal , i would myself try to avoid taking
the door frame out if at all possible . You should be able to replace the
seal it's self with out removing the frame .
With all aluminium rails / frames you should try to avoid bending them out
of shape , it's difficult but not impossible , if you do bend them you can
reshape them by very gentle bending .

This info should be enough to get you started , feel free to ask as many
questions as you like , be glad to help .
Where abouts do you live , if it's not to far from me i could possibly pop
over and have a look .
Although when you see how bad the damp is it can be soul destroying , the
thing to remember is it IS fixable . If you do the work yourself it's can be
done cheaply .
My first caravan ( the Sprite ) is still going strong and still bone dry
3years later , it didn't look like the original wallboard because i couldn't
afford the manufactures stuff at the time ( still can't LOL ) but the repair
blended in well with the rest of the caravan .
I'm no expert on caravan damp , i just try to help/advise where i can .

atb
Wizard