Elddis split gas locker door anyone? Warning!

Has the caravan been serviced in line with the warranty requirements? Was any additional warranty offered by the dealer when you purchased the van? You need to press the dealer on this if nothing else will they contribute to the cost of repair? Was any of the purchase on finance/credit card? If so may be worth speaking to the finance company to see if they can bring pressure to bear.

As the OP, I can only sympathise.  With the benefit of hindsight I now know that the cracking is due to the poor design of the gas locker door.  The struts are far to strong for the weedy door design so that every time you open/close the door it flexes the hinge mountings. The hinge is only screwed to the front panel so at each screw hole the panel then cracks. Left alone the cracks then travel up to the windows. And when that happens it's game over - the whole front panel has to be replaced!

In our case we traded in the caravan as we couldn't afford to spend any more money on it.

Elddis clearly don't comprehend (or don't care) that buyers may have limited funds.  In our case this was to be our retirement caravan - bought with lifetime savings.  We naively expected a brand new caravan to be trouble-free. So we had to find further precious savings to switch to a Knaus Starclass.  The build quality of the Knaus is in a totally different class to the Elddis so we're now finally happy with our new retirement caravan!

We have just had a similar issue with our Elddis affinity 554 and we’re shocked to be told today that we’re out of warranty. Not sure what our next move is but the crack is only going to get worse. I’m interested to hear how you have moved on with your repair.

Stop drilling the end of cracks works. If you find they have continued then you missed the end as difficult to see sometimes. Make second one at the new position.  Mine have not moved in the last 2 years having also removed the oversize/powerfull gas struts. A 3mm drill is a God size.

This is a proven method in the engineering  world which I have had to use alot in the past on aluminium hulls.

footlooserv wrote "A 3mm drill is a God size."

Are you sure? https://www.amazon.com/ 

Yes exactly the same. Plastic bin lid split at hinge about 6mo after I bought Elddis Avante 576 in 2016. Did not go back within 12 mo so they would not repair. Door warped. Don’t fancy spending lots of money on this. Trying to repair (at last!).