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Old 01-15-2005, 03:10 PM   #99
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Continuing forward on the streetside I've uncovered more of the frame, which still appears to be solid, and the forward corner outrigger, which is also broken off. Not to be picky, but the welds that have broken on these outriggers don't appear to have been all that thick to begin with. So now I'll have two jobs for the welder.

I took a break because as I continued forward I ran into the POs front patch, which was installed using a butt strap. So now I have to deal with wood twice as thick, and rusted out screws set down into the wood. I got tired of that real quick.

Having delt with a lot of rust on my classic mustangs, I was fearing a lot worse, and so I'm pretty happy that so far the main frame channel appears to be in good shape.
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Old 01-15-2005, 03:59 PM   #100
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Steph
The fastener in your picture of the "U" channel is a screw. It looks like a staple because mostly corroded away. I replaced all of my screws with #10 x 5/8 zinc plated round head steel screws.
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Old 01-15-2005, 04:33 PM   #101
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Steph

So you found the front outrigger broken... isn't that what started this whole project was the bouncing of the front and a possible outrigger broken - sounds like we now know why that was happening and you'll be able to fix it.

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Old 01-15-2005, 05:10 PM   #102
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Wow Steph your right into it.

Couple things of note.

The wiring for brakes is in the belly and that might include the feed line for the emergency brake switch on the tongue and jack. All wiring for running lights and interior items will be through the roof. So on you 7 wire plug the feed to change the battery and the brakes will be in the floor the other 4 (number 5 is the ground wire to the A-frame) will be going up into the front wall.

Before you put the floor in check the brake wires carefully. It would be a real pain in the butt to have to rewire after the floor is back in.

So do you think your broken outriggers might be from being over hitched or just loss of structure from the rot in the floor? What did the PO pull with?
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Old 01-15-2005, 05:11 PM   #103
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Yup, that's two broken outriggers, both on the same side in the front, plus lots of rotten wood - some of it I was able to easily break off by hand! Definitly could have been causing my problems.

Thanks for the headsup Greg, I just got a recip saw so I'll be cutting through those fasteners when I get more of the floor taken out.
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Old 01-15-2005, 05:18 PM   #104
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Steph, I have kind of a dumb question, and I'll be the first to admit, I skimmed the thread since it's so long.

How long do you think you'll keep this coach? I recall that you really love it and that's why I'm gonna kind of say throw this out there just from the point of a couch coach here.

Given the amount of work you've done already, if you plan on holding this beauty for a long time, have you considered doing a straight body off resto of the entire floor? I mean from the pics I've seen, you are well on your way. I know it would add significant time to the project and maybe more $$, but I was way impressed with how well you work on cars that this sort of seemed like a good match.

If it were me and I had the skill set you do, I might consider it since you could very easily do it all at once an not have to revisit for a long time. My concern with the current setup is that you could piecemeal this issue, find another one in a few years, have to do that, when now, you have it pretty well ripped up, welders on hand, etc, why not just go full monty and lay a whole new floor down and do all welding at one time.

Keep in mind as I said, I'm playing the couch coach here.
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Old 01-15-2005, 05:29 PM   #105
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No problem, I can see why you'd think that. Actually after poking around I'm pretty well convinced the back half of the floor is fine, so I'm saving a huge amount of work by not pulling out the one piece fiberglass bathroom, and all associated plumbing. The work I'm doing in the front will be to replace the damaged areas which are confined nicely to the original front plywood pieces. The pieces further back are solid. My only dissapointment in confining the work to the front is I won't get to add a grey tank. But we can live without that, the blue boy is not that inconvenient to use.

We do love the trailer, and still think it's the perfect one for us (though others keep warning me the desire to upgrade to something larger will strike sometime). In fact we were just discussing if there were any interior changes we should make while it's apart, and can't think of any, beyond upgrading appliances. We spent almost four weeks in it last year on three seperate long trips, and really enjoyed it.

Lesson #1 from the cars, don't tear anything down any further than you absolutely need to! My goal is to have it ready to camp in again by spring. If we find more trouble in a few years, we'll just spend another winter with it apart then!
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Old 01-15-2005, 05:38 PM   #106
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Makes sense to me. Being a couch coach, one never really knows what's on the playfield totally. Glad to hear the rear of the coach is all good.

As for the bug your friends told you about.....well, it bit us, but it was the kicking the dog dish that did it for us. Now Penny has her own little nook in the front of the Safari where she is comfy and out of the main traffic areas.
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Old 01-15-2005, 09:51 PM   #107
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I'm ashamed to say I don't think we took the dogs with us a single time last year! Even though I bought it so they could travel easily with us. Since we work at home and are with them all the time, it was so nice to get away from them now and then! And the little one has decided she doesn't enjoy riding in the car as much as she's gotten older. So making room for the dogs has become less of an issue, and the petsitters come take care of them instead. So hopefully the little trailer will suffice for the two of us for some time to come.
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Old 01-16-2005, 04:34 PM   #108
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Well past the point of no return...

I continued cutting out pieces of the floor today until the jigsaw blade bent, and then I bent the circular saw blade as well. I guess my technique needs work. It's the first time I've used a circular saw, so now I know what not to do! Anyway, I don't have any spare blades, and we're on the tail end of an ice storm today, so there's no going out to the hardware store.

Here's a pic of another big piece I got out, with a shot of the underside still covered in the spray on insulation. This stuff is icky, with what looks like mold on it, and most of it had broken away from the outer pieces I'd cut out so far. This piece was towards the middle of the trailer and was the first one I'd pulled out where the insulation was intact.

I'm cutting away the center of the floor to make it easier to get to the big patch in the front. I'm working my way around it, hoping to find a better way of getting it out. It's a good patch I guess, it doesn't want to come out easy! But there was plenty of rotten wood along the edge of it, so the whole thing does need to be replaced.
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Old 01-16-2005, 05:09 PM   #109
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Don't know if this has been mentioned - but hope you are wearing a respirator

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Old 01-16-2005, 07:52 PM   #110
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Yes, someone mentioned it earlier in the thread so I went out and bought one! I've been wearing a respirator, safety goggles, earplugs, and leather gloves. It is one nasty, dirty job - I'll be so glad when this part is done!
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Old 01-17-2005, 11:15 AM   #111
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Taking apart is not fun at all, but I'm finding building/rebuilding new stuff is a lot of fun.

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Old 01-17-2005, 11:38 AM   #112
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I'm afraid this is going to be expensive

Stephanie,

Please post pictures when you finish this job. We are still in awe of you!

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