Finally, the wood is on the frame. I still have to do one of the other Elevator bolt, but that will come when the shell is back on. ( Hopefully Friday)
Today I made a few new sections of floor channel, from leftover .032 aluminum. I could have alo used some of the old belly material, but I still need it for templates, to cut the new aluminum.
There is a sequence of photos below, showing how I did it.
First, I cut some 3in by 30in long strips of aluminum. Then measured and marked a 1.5in strip down the center of it.
The third photo shows the material in the benchtop metal brake. The first bend makes one side of the c-channel, the second bend makes the other side and the bottom of the c-channel. The last picture shows the finished channel section. I can only make 30in sections, since this is the maximum capacity of my bending brake. This tool has come in quite handy at times, making brackets, lamp shades, tubs etc. I also used it to fabricate repair panels for my wheel wells.
I will spend the next few days installing the channel to the shell, temporarily, usig #8 sheet metal screws. On Friday Murray ( Creampuff) and myself will lower the shell back on the floor for the first time. It will be sooo much easier with 2 people. Maybe I can get Airhead over here also. Hey Guys, Pizza on me!
What are the odds that another Airstreamer picked up an Overlander on the same day? I bought and retrieved a pretty nice 1962 Overlander. I own customized 1961 Flying Cloud that I will be selling soon. My wife and I decided on a tandem axle unit with all the amenities. We also pull our trailer with a 1500 series Suburban.
I would like to hear more about your project and see some interior shots. I have begun removing parts and assessing the scope of work. My Overlander is pretty solid all around with exception of roof damage caused by A. an idiot walking on the roof to remove the old AC. B. another idiot who installed a roof antenna mount by drilling a 1.5 inch hole through a support rib.
Okay...so I am fairly new to the forums. I should have noted the date on Uwe's initial post. It appears he is months into a refurb on his Overlander. Anyway, it is good to read through the thread and see the project evolve.
Last Friday the shell came down. Thanks to Murray (creampuff) for his diligent help!
We lowered the shell on the new wooden floor, traced the rear contour, lifted it back up, cut the floor to fit, and dropped it back down.
Sounds easier than it was. It took 3-4 tries to get the gap just right for the belly material and the channel etc. A real pita, if you ask me!
Note to self: Next trailer should have at least remnants of the original flooring for templates.
We also re-inforced the body bracing so I can use a jack on them to lift the front or rear individually, for belly wrap and floor channel installation.
But at last the shell is no longer hanging on the ceiling, and I can move the trailer around again. Can't wait take it out to the parking lot Monday and clean the shop floor underneath.
Thanks Murray!!
Cool - congradulations! Now that I think of it - your probably gonna kill me, I could have traced the curve on some paper and overnighted it to you - Now I think of it.
Worked a bit here and there on the old girll over the last 4-6 weeks. Insulated the floor from below, using closed cell foam sheets and styrofoam. Got the outer section of belly wrap installed from the front tire on one side to the front tire on the other side. Measured, ordered, and picked up my fresh and grey water tanks, and found 2 reference points for the rear channel mounting bolts.
Found out that my rear curve appeared to be about an inch too long. Removed channel, cut floor, re-installed channel to the old, original location. The shell has been sitting suspended by jackstands on it's new floor.
Today Murray is coming to help me permanently install the shell, after finishig the outer belly wrap around the rear. Exciting! Progress!
Pictures to follow.
The shell is back on! IT was a long day, and lots of pushing, shoving, prying, sweating, a little swearing, lifting, dropping, measuring and eyeballing.
Fortunately it was not a very hot day today. I took some pics, will post them on Monday.
Hre's some shots of the trailer from this morning. You can see that the circumference is not riveted yet. The whole shell is only secured by 6 or so sheetmetal screws. It needs a lot of adjusting and situating yet.
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