1957 Caravanner Full Monty

[jjmtb]

Originally Posted by Bubba L

I just went through the top shock mount issue. We also received our axle from Colin and it turned out great. Don't remember the shock Colin recommends, but that is the one we used. We have a thread on our 55 renovation that shows pictures on how we fabricated the mount bracket. "Tale of a 55 FC Whale Reno" should show the way we made it. It is tight in the wheel well, but the shock can be replaced someday if needed. Just make sure you place the bolts appropriately where you can remove the nut and shock easily. Good luck. Bubba

Bubba-

I reviewed your thread. I am just having trouble visualizing it. Maybe I am way off with something. I got the axle from Colin. I fab'd the mount to the drawing he said. I just can't see how the shock mounts in all this. Is the flat plate for the shock or axle mount? How does the shock mount fit vertically?

[Bubba L]

I'll take some pictures in the morning and send them via a PM message. I'll make a little sketch and also send that. I also made the brackets per Colin's sketch but decided to make a longer plate to spread the load farther fore and aft of the axle load point. At any rate, i did weld the shock bracket to the mounting plate. The bracket is at an angle due to the axle tube. But the bracket hole where the top of the shock mounts is directly above the lower mounting hole on the axle. I'll get you something in the morning. Bubba

[jjmtb]

Thank you. Much appreciated.

[Bubba L]

This is a sketch of how I did it. I lengthened the mounting plate to spread the load down the mainframe. This also gave me a good point of attachment for the lower end of the shock bracket.




You can see in the below photo that we used a 3" spacer plate welded to the mounting plate. We had to do this because our wheel well was only 13" deep at the top of the wheel well. We had to get the shock bracket out far enough to clear the wheel well.


This last shot shows the nut (attaching the shock) at the lower point of attachment facing the mainframe so that it can be later removed.


Hope this helps. Let me know if you need anything else.
Bubba

[jjmtb]

That does help. I feel like I am finally moving forward.

[jjmtb]

I apologize for the lack of updates. I have gotten a bit of work done on the camper. All frame repairs have been made. A new step has been welded on. The new axle and wheels are on. The frame has been wire brushed, metal prepped and POR-15. I got the subfloor back into place.

Unfortunately I don't believe I would have gotten the plumbing and belly skin done in time for the top to go on before winter. Since I was still borrowing space in a family members garage and couldn't keep the top there any longer I had to put the top on temporarily and bring the entire thing home. That meant moving gantries between two states, dropping the top on, scrapping all my new c channel by riveting it all back together, and driving home without belly skin. But, I did get it all done and tucked Sylvie in my garage.

[jjmtb]

Pics

[jjmtb]

[DDickey]

I remember feeling a deep sense of accomplishment when I got the shell back on.

[jjmtb]

It did look and feel pretty awesome to see it together and being pulled down the road. Unfortunately I get to do it all over again.

[DDickey]

Did you make a mistake?

[Bubba L]

jjmtb, I know it seems disheartening to place the shell and have to pull it off again, but that may be a good thing. We dropped our shell twice before the final third time. Kept leveling, tweaking and trying to remember things I may have forgotten before the final attachment. I hate you had to relocate your project, but at least you had the satisfaction of seeing the shell attached. It's looking great and your doing terrific job.

[DDickey]

So when I dropped my shell I sat 'er back down, thought it was all good and got to riveting. So much goodness. Only later when I started putting the interior skins on did I notice that the street side rear of the shell was dropped 1/4". It was too late to correct it when I found the problem. No one will ever notice it but me, and maybe someday I'll forget about it, but it bugs the hell out of me right now. Better to get it right while the getting right is available to you

[jjmtb]

Thanks all. While it was discouraging to have to reattach the top to move it the process wasn't all that bad. I got to teach my wife how to rivet. She did a great job with the bar. I had been wondering how I was going to buck all the rivets as this job goes on and knowing that my wife can help was a resolution to a big piece of the puzzle.

All together, it only took about 4 hours to put it back on and rivet it together. We got into a pretty good rhythm and was ready to pull her down the road in no time.

I used the existing curved extruded channel (front and back) to use as a guide to locate the shell with clecos. I then used the existing holes in the straight sides as a guide to drill the rivet holes in my new side channel. It worked well. All I have to do now is get more of the bent c-channel made and refit it all. It is a minimal investment (less than $100) except for the time.

It was pretty exciting pulling it home. It was a 220 mile trip. With the new axle and wheels I had no worries. Now that it is home it is a big relief and the options to work on it are endless. I also got a few thumbs up from other travelers with that beauty on the back.

[jjmtb]

Originally Posted by DDickey

So when I dropped my shell I sat 'er back down, thought it was all good and got to riveting. So much goodness. Only later when I started putting the interior skins on did I notice that the street side rear of the shell was dropped 1/4". It was too late to correct it when I found the problem. No one will ever notice it but me, and maybe someday I'll forget about it, but it bugs the hell out of me right now. Better to get it right while the getting right is available to you

You are absolutely right. I found a few places that the floor could have fit better. The thing is that the places where I could adjust my panels are exactly the same profile as the old ones. I get to make them fit better.

Also, there are some spots where there is interference with the ribs in the shell and the floor channel. I remember it was that way when I took it apart. Now I can mark it all and adjust for it. I like being able to do that. The only problem is that this could take me down a rabbit hole that I may never be able to get out of. At some point you have to put it together but my OCD may disagree.

[jjmtb]

It is no doubt that this project is going to take a lot of work. I think that is a fair and established conclusion. The problem is that I would really like to get some shiny camping time. The other issue with this project is that I have to fit a family of five in this small camper. To do that I planned to have no bathroom and triple bunks in the back for my kids. Space is going to be tight and the need for super customization huge. The time it is going to take me to get to the point of use is going to be a while.

So... what to do? What are my options? I need more interior space and time to work on Sylvi at my convenience and as the budget allows.

I got it... get another Airstream to use now. Get one that is bigger and usable. Then I can put a more original floorplan in that I do not have to worry about fitting 5 people. Plus, I can take my time and have less worry about getting it done to use.

Drum roll please... I found this gem locally. A 1965 Overlander. It checks all the boxes and is in ready to use condition. I am not saying perfect but the electrical works. The plumbing works. The propane works. The original appliances work. It is clean. The wheels are new with new brakes. The flooring has been replaced. There are no big dents or scratches. The one dent in the street side is the size as if you used your middle finger knuckle and pushed in the size of a penny. Everything is original. All the windows are intact. Half the cranks work half are stripped. The only real mod done to it was turning the rear bath into a bed. The black tank is new and in place but instead of the bath there is just a sheet of plywood over everything making a bed frame. The A/C is gone and covered up and the front skylight vent thing broke long ago and was covered up. It is totally usable and towable.

I am totally pumped about this thing. Pics to follow.

[jjmtb]

[DDickey]

How much did you have to give, if you don't mind saying?

[jjmtb]

Originally Posted by DDickey

How much did you have to give, if you don't mind saying?

Pm'ed

[jjmtb]

Had to get Sylvi in the garage. It is going to be cold and snowy in WI soon. I still have a window out and all the roof vents off. I can't put new ones on because I have to take the top off again. I have a garage with 8' doors.

It took me less time to get the top back on than try and get this thing in the garage. With the vents off I had to get down another six inches. I thought I would let air out of the tires but that only got me 3". I pulled the wheels off and cradled the brakes in appliance dollies. I used a floor jack on the back to pull. Many hours and lots of "motivational words" I got it in. Jacked her back up and put the wheels back on. Attachment 1