Every week at Ozzy Auto Electrics, we see a range of electrical issues in caravans — from minor inconveniences to dangerous wiring that poses a serious fire or shock hazard. Often, these problems come from DIY installs, rushed jobs by non-specialist auto electricians, or budget installations that cut corners.
We’re passionate about doing things right the first time — and keeping your family safe on the road. So, here are the seven most common electrical mistakes we see on caravans, plus how to avoid them.
Wrong Cable Size
One of the most dangerous and common errors is using cable that’s too thin for the current load. Undersized cable causes voltage drop, heat build-up, and in extreme cases — melted insulation or fire.
How to avoid it: Always match cable size to the load and distance. At Ozzy Auto, we use oversized cable for long runs and high-draw items like inverters and fridges.
Poor Crimping and Termination
Loose, poorly crimped connections cause arcing, corrosion, and intermittent faults. This usually happens when low-cost tools or connectors are used.
How to avoid it: We only use ratchet crimpers, heat shrink terminals, and quality plugs. Every joint is tested, secured, and strain-relieved.
No or Incorrect Fusing
Fuses are your safety net. Without proper fusing, a fault can result in melted wires, fire, or system failure. We’ve seen lithium batteries connected without a single fuse — a disaster waiting to happen.
How to avoid it: Every power line should be fused as close to the power source as possible. Ozzy Auto uses correctly sized MIDI, MEGA, or blade fuses mounted in accessible positions.
Inadequate Charging Systems
We often see AGM batteries being charged from a smart alternator with no DC-DC charger. These batteries never fully charge, meaning poor performance and early failure.
How to avoid it: We spec the correct DC-DC charger for your battery type, usage, and system size — Redarc and Victron are our go-tos.
No Battery Monitoring
Without a proper battery monitor, it’s impossible to know your true State of Charge (SOC). Relying on voltage alone is inaccurate and often misleading.
How to avoid it: Install a SmartShunt, BMV, or Cerbo GX to get real-time data on power in, power out, and SOC. We configure, calibrate, and teach you how to use it.
Overloaded Inverters
Running a 2000W inverter on a 100Ah AGM battery without appropriate cabling or ventilation is a recipe for tripping breakers or killing your battery.
How to avoid it: We calculate real-world loads, size the inverter properly, and match it with a battery that can handle it (usually lithium), with correct RCD protection.
No Planning for Expansion
Many systems are installed with no thought to future add-ons. Want to add Starlink later? Or another fridge? Poor design limits your options and increases costs later.
How to avoid it: Our systems are modular, expandable, and well-labelled. We think ahead — even if you’re not ready to install everything on day one.
In Summary:
Electrical systems aren’t just plug-and-play. They require smart design, quality parts, and skilled installation. Ozzy Auto Electrics stands for long-term performance, not short-term shortcuts.
BOOK OUR HEALTH CHECK SERVICE TODAY TO INSPECT YOUR CARAVAN, CAMPER OR MOTORHOME.
Your safety and comfort on the road depends on it.
