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Stanley29 · 02-12-2016, 08:33 PM

went with 2x4x.083 for cross members and 2x3x.083 for outriggers. Had to use a 2x4 for the 2" outrigger since I ran out of 2x3. Don't think it will present a problem.

Stanley29 · 02-17-2016, 11:22 AM

Did some checking on getting my springs re-arched. Cost could be between $100 and $250 depending on what happens when the springs come apart. My quote for a straight dexter axle minus the springs was around $520. So now Im thinking about a torsion control axle. Best price I could get was around $800. My springs on one side of the trailer sag so Im thinking there is a problem there. Does anyone know anything about angles of drop on the Torsion arm? Im getting ready to order one and not sure what works the best. Thanks

Stanley29 · 02-17-2016, 03:46 PM

$520 from American trailer supply for a torsion control axle or $337 for a springs straight axle with new springs and all the hardware. No wait for the spring axle. Thanks to Top for the lead on American Trailer supply.

Lance M · 02-17-2016, 05:09 PM

You are welcome

Rockwell American is a great Texas company.

66Overlander · 02-17-2016, 06:34 PM

Quote:

Originally Posted by Stanley29

Not sure if Im going to go with a torsion control axle or not. I got a quote from Colin Hyde for a torsion axle but after speaking with a few other guys Im thinking maybe I will stick with the old drop style with the leaf springs. Hell it was good enough for Wally and he went around the world on dirty roads. Might be easier just clean up the old springs and strap the new axle on. I think my trailer has 10 springs

Just to be correct, all Airstreams that paticipated in the 1963-64 Around The World Caravan were required to have torsion axles. This requirement was set because of all the problems experienced on the 1959-60 African Caravan where many broken axles and springs were experienced, except for Wally's gold trailer that had a prototype torsion axle.

That said, if you are not going to be pulling your Airstream over jungle roads and rocky trails, a leaf spring axle should also work fine.

Greenfire · 02-17-2016, 07:20 PM

okay, if this shows up three times, it's cause the forum is messing with me! Trying to get it to show up one time!

Did you do the welding yourself? I think I read that a friend was going to teach you, if so, about how many hours did it take to learn so you were confident you'd do a good job? Asking because there is a course near here to learn welding for hobbyists, but it's 16 hours and I'm thinking it's a bit of overkill. (particularly since I haven't even seen my frame yet to know what shape it's in!)

Stanley29 · 02-18-2016, 10:07 AM

I had a buddy show me how to use the machine. A Powcon 200. Its a 220v machine with a wire feed. He brought over some steel for me to practice on and I went at it. He showed me how to adjust the machine for heat/amps and speed of the wire. Then I watched several youtube vids so I understood exactly what I was trying to do. I think once your over the shock of pulling the trigger you can concentrate on the job at hand. You start to see the puddle and the wire and how to control the puddle. Just a little practice. The last welds were much better then the first ones but my buddy thinks they will all work. I can tell you I tried to saw one off that I didn't like and that sucker was on there.
To answer your question I think the 16 hours is a bit much. I definitely think there is skill involved to being a good welder but its not Rocket science. I keep telling myself on this project…your not building a 787 Mike. Go for it welding is a blast. Cheers, Mike

Stanley29 · 02-18-2016, 10:11 AM

Quote:

Originally Posted by 66Overlander

Just to be correct, all Airstreams that paticipated in the 1963-64 Around The World Caravan were required to have torsion axles. This requirement was set because of all the problems experienced on the 1959-60 African Caravan where many broken axles and springs were experienced, except for Wally's gold trailer that had a prototype torsion axle.

That said, if you are not going to be pulling your Airstream over jungle roads and rocky trails, a leaf spring axle should also work fine.

Have you been down the Grapevine lately. Probably worse then the jungles of africa

Stanley29 · 02-29-2016, 07:45 AM

Help me Mr Wizard,
Im having a little frame issue. When I got the trailer the left rear side of the trailer sagged…probably from the gigantic steel tank that was positioned just aft of the left wheel. I noticed and figured it was just the left springs sagging. I repaired/welded new cross members etc etc. After taking the axle off Im now discovering the left rear side might be bent. Im thinking I might have to saw the cross members off aft of the wheel on the left side….make sure the frame is plumb and then weld back on. Maybe replace the left main rail. Has anybody experienced this issue with a frame? Cheers, Mike

Stanley29 · 03-08-2016, 06:59 PM

After a multitude of honey do's I finally got back to the airstream. Cut the bumper off and straightened it with a press. Came out ok. Dropped the frame flat on the ground and welded it on hoping this would fix my drooping right corner issue. No luck there

Stanley29 · 03-08-2016, 07:04 PM

Started on the front end cap. Now that it is a bit warmer here in Oregon Im hoping the paint stripper does a better job then my first attempt on the rear end cap. Its coming off but man what a pain in the ass

Stanley29 · 03-08-2016, 07:12 PM

Rigged up a little rotisserie. Works alright for now but Ill have to improve on it after I install the floor. Managed to get the frame back straight. Propped up the low end and used my tractor front loader to push the other end down. 3rd attempt straightened her out. Ill make sure she's level before the floor goes on

Stanley29 · 03-08-2016, 07:18 PM

bought the plywood today for the floor. went with a 3/4" maple they had on sale at a local bargain lumber store. 11 ply…$33 a sheet. Sanded on both sides…I think it will work. Now I have to figure out where to cut it. Outrigger to outrigger? I replaced most of the outrigger and cut them to 15". The old ones were all different lengths. 14"..14 1/4, etc. Does anybody have some good advice?

66Overlander · 03-09-2016, 08:21 AM

Just threw out all of my old notes from when I replaced the floor in a '55 Airstream that I used to own (that likely was similar to your '54). I think I had to cut that floor about 84" long in total, if I remember correctly (don't trust my memory, though, because that was several years ago). The floor did extend out slightly from the ends of most/all outriggers when installed as I remember it.

On my current '62. The floor probably extends 1/4" to 1/2" inch beyond each outrigger, but this trailer is wider and I think I cut the floor to about 86" or 87" (still have my notes on this one, but didn't go look for them to confirm my memory).

If you braced the shell very well before you removed it, you could go measure the distance between the inner edges of the floor J-channels and add about 3" to determine your floor width, because the floor channels should be about 1.5" wide each. I'd measure a few places and average them out to select the floor width.

Remember that the floor channel is designed to bolt thru the ends of each outrigger, so the floor needs to sandwich between the floor channel and outrigger. Hopefully at 15", they outriggers do not extend too far and cause the shell to bow out in an unnatural shape when reinstalled. But since the shell is very flexible, it might accommodate a small width increase, but then some of the cabinet fits to the interior walls will change.

Also if the outriggers are too long, getting the belly pan curves to fit may be difficult. Certainly don't want the ends of the outriggers extending past the edges of the plywood floor and outer edge of the floor channels. A slight gap between the ends of the outriggers and the belly wraps is not a problem - the aluminum will follow it's own curve without developing witness marks from the outriggers.

Good Luck!

Stanley29 · 03-09-2016, 10:38 AM

Thanks for the heads up Joe. I think I will brace the J-channels and take measurements like you suggest. The shell is not braced at the moment. What is discerning is the fact that a lot of my outriggers were of different lengths. Some as much as an inch. I do remember some of the floor was hanging over the outriggers in some places. Time to quit talking and start a cutting. Cheers

MarkR · 03-09-2016, 11:02 AM

from where I'm sitting, adding 1/2" or more to the outriggers could cause some "grief" down the road (when you go to reinstall the shell) . . . assuming you also add 1/4" of plywood overhang . . . and for what it's worth, my '51 flying cloud plywood was 85" wide (w/ a 1/4" of overhang over the outriggers).

(thanks for documenting your project - looks great)

Lance M · 03-09-2016, 12:12 PM

85"

66Overlander · 03-09-2016, 12:16 PM

Quote:

Originally Posted by Stanley29

Thanks for the heads up Joe. I think I will brace the J-channels and take measurements like you suggest. The shell is not braced at the moment. What is discerning is the fact that a lot of my outriggers were of different lengths. Some as much as an inch. I do remember some of the floor was hanging over the outriggers in some places. Time to quit talking and start a cutting. Cheers

If you didn't cross brace tje shell before separating it from the floor and frame, it may not be in the exact same shape/width now as before removal. I think you then just need to work off the frame itself. If the longest outrigger was not more than 14.5", I wouldn't make any of the new ones any longer and then I'd measure across them, edge to edge and then make the floor 1/2" to at most 1" wider.

That is, unless you still have the old floor that was removed to use as a template.

Stanley29 · 03-09-2016, 05:17 PM

After more measurements I committed on 85". Managed to get the floor in place and all the cuts minus the radius cuts for and aft. I cut all the boards at 85" but now after looking at the front of the shell it looks like it bulges out a tad. Same with the rear of the trailer. Im hoping this is just because I do not have the sides braced. I bolted down the floor and Im fixin to roll her under for a better look see.