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Old 06-20-2005, 01:40 AM   #29
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More progress

Hi all, I have successfully replaced my belly pan ! yay ! I have to put the corner wraps on and rivet the skin to it underneath but the main part of it is done. My hands are sore from trying to roll the .040 up under the front of the trailer. I like the thickness but it sure takes a lot of strength to hold it in place and drill holes for the rivets.

I made a little design change ( next to the frame ) up front to try and keep water from getting in while driving and washing. I made a piece of angle from the scraps of .032 2024T3 I had and riveted it to the frame and the belly pan. I put a lot of Vulcem in between the aluminum and the steel. We'll see if it works or not. If it doesn't, it will still be far more stable up there anyway. Here is a pic of the streetside.

Something else I changed was I put one vent hole in each corner of the interior. In the "u" channel between the outer skin and the inner skin. I used aluminum screen and a plate on top to hold it down. I have a pic of that in the members photo section. I am thinking that this will help dry things out if they should ever get wet in there, and they will, it's inevitable. The only place I sealed the belly pan was in the front along the frame rails, in the wheel wells, and at the step. I am also thinking of putting some small vents in the pan itself. I found some 2" vents that are aluminum at HD that I think would work. Not sure if I really need to do this at all. I can do it later at any rate.

I also put new screen on for my bottom fridge vent and cut an access hole for my 12V electrical connection place, which I moved from the front to right behind the step. It seemed like a logical spot for it. I just wanted one place to make connections.

I broke two drill bits dulled another one. Got three cuts from the aluminum and a tan on my legs while they were sticking out from under the trailer, lol. I ran out of rivets, both olympic and the large ones that I used to attach the belly pan with.

The underside looks really wonderful now ! mucho better than before.

Thats about it ! Enough for one day huh ?
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Old 06-20-2005, 02:55 PM   #30
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Floor sealer

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Originally Posted by C Johnson
Oh my oh my, how wonderful it is to have a new floor back in the Caravel. I still have to make new corner pieces for the belly pan and then I can permanently attach the skin back to the floor. I also put in about 2/3 rds of my insullation under the floor. I routed my new 12v cable for the running lights as well. Felling a bit less overwhelmed now. I am taking most of the day off from the AS tomorrow. I need a break now, a little r & r is in order. Pics of the progess in the members photos section.
Hi CJ, can I ask what you used to seal the edges of the new floor you layerd down?
I am doing the same thing and have heard many diff solutions: epoxy, stain, boiled linseed oil. Yours looks fairly well sealed, I'm dying to know what you used.
Also, what size elevator bolts did you buy? I am using 3/4 ply for the floor. Thanks
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Old 06-20-2005, 03:45 PM   #31
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Good job on the bellypan! That's a tricky job!

I find I have on occasion had a leak inside, and the water sloshed around in the bellypan until it found it's way out. So if your seams are super tight, you might want a small opening in the low spot to let water drain out in case any somehow gets in.

I'm not sure about the vents, but I was thinking that would be a good idea too, as long as they didn't let in more water than they helped dry out!
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Old 06-20-2005, 08:30 PM   #32
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Hi Albert, I used an oil based, mold resistant, primer made by Zinnser(sp) I put on 2 coats. It soaks in very nicely. The water that did get on it beaded right up and I could wipe it off. I didn't do the whole floor on the topside bit I did do the entire bottom and edges. I wanted untreated wood under the vinyl flooring so the glue can get a good hold.

I used 5/8 acx - exterior ply. Same glue as marine, but has more voids than marine.

The elevator bolts I used a are 1/4-20 x 1 1/2" long. I bought a box of 100 and used 94. I used torque nuts and them bet them over just like they were when I took the old ones off. Some things I saw no reason to over engineer it. There is a pic of the bolt configuration that I used in my members photos.

Chris
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Old 06-20-2005, 08:34 PM   #33
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Hi Steph, Thanks ! It was worth it to change it out rather than try to fix all the problems with the old one.

Yes, I was wondering about the same thing on the vents in the belly pan. I at least wanted the ones inside the walls. I know water won't be entering those.

Chris
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Old 06-21-2005, 12:33 AM   #34
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Arrow Thanks a bunch

Quote:
Originally Posted by C Johnson
Hi Albert, I used an oil based, mold resistant, primer made by Zinnser(sp) I put on 2 coats. It soaks in very nicely. The water that did get on it beaded right up and I could wipe it off. I didn't do the whole floor on the topside bit I did do the entire bottom and edges. I wanted untreated wood under the vinyl flooring so the glue can get a good hold.

I used 5/8 acx - exterior ply. Same glue as marine, but has more voids than marine.

The elevator bolts I used a are 1/4-20 x 1 1/2" long. I bought a box of 100 and used 94. I used torque nuts and them bet them over just like they were when I took the old ones off. Some things I saw no reason to over engineer it. There is a pic of the bolt configuration that I used in my members photos.

Chris
The only thing I still question is the floor plywood thickness. I hope mine isnt 5/8 after I bought the 3/4 marine ply. It was really hard to measure the ply still on the floor and I tossed the rotted stuff before trying to measure it. I guess I can sand down the difference.
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Old 06-21-2005, 01:45 AM   #35
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Hi Albert, You should be fine with the 3/4 in ply. It will raise up the skin 1/8 of an inch. That's if you had 5/8 to begin with. Mine was 5/8. They may have used 3/4 in. in the newer coaches, I am not sure about that one. If you have to, you can always run a router around the outside edge to bring it down to 5/8. You might ask around here and see if anyone knows what the thickness of the ply was in 1970. Good luck on your project !

PS - on the bolts, I countersunk them into the floor about an eighth of an inch and then I am using a filler over them to get a smooth surface.
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Old 06-24-2005, 10:39 PM   #36
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Just thought I'd let ya'll know. I don't need the jackstands anymore ! I bought my tires today and put them on. I had to go with 14" rims rather than the 15's that were on there. Couldn't get a small enough tire for the 15's. So if anyone wants 3 15 inch rims with 2 new coats of por-15 let me know. I'll let ya have 'em for a few bucks. The size is 15 x 5 1/2 on 4 1/2. They are Kelsey hayes wheels.

It sure looks good setting on it's own tires again ! I'll take some pics tomorrow.

Chris
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Old 06-26-2005, 01:02 AM   #37
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Update on project 2005 - new pics

New pics The latest pics show how much the axle has raised the trailer, the finished axle install, and the new black water tank
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Old 06-26-2005, 12:00 PM   #38
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I am SOO impressed! I just looked at your pics. Great documentation.
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Old 07-01-2005, 03:18 AM   #39
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Quick update

I took off the rooftop a/c unit. Wow, that thing is heavy, no wonder the roof sagged there. I am not entirely sure if I will be putting it back on as I usually boondock with no 110. I only have one more corner left to do on the bellypan. I got my pkg from AS dreams. The new vent pipe covers look great, can't wait to install them. This weekend is dedicated to getting as much done as possible. I'll burn the candle at both ends, up the side and down the middle
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Old 07-01-2005, 09:43 AM   #40
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Good luck, Chris, you're doing a heck of a job!

BTW, I have no AC and haven't missed it much. There's not much in the NW that can't be remedied with a good fan or a shady spot by a stream - if you know what I mean Actually our hottest trip ever was a weekend in Sisters in July, where we spent most of our time touring in the van with the AC on. It was just toooooo HOT! But otherwise I've never found myself wishing for AC.
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Old 07-01-2005, 10:40 AM   #41
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Chris - we have toyed with the idea of removing the AC unit as well. We have NEVER used it (other than testing). You could put in another Vent or maybe a periscope......
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Old 07-02-2005, 11:57 AM   #42
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Janet, I don't think I will be putting the a/c unit back on. I have been looking at the maxxair vents and fantastic fans for a replacement. I could never sleep with the a/c on anyway. It is wayy too loud. If I ever do put one back on it will be a penguin low profile unit and laurelhurst heating and cooling with be doing the job.
Other news : I picked up my brand new aluminum refer scoop yesterday ! It looks pretty sweet ! and it'll last forever. I'll post some pics tonight. Have to go shag the rest of my parts today. Then it is put it back together time ! yay !

Chris
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