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Keyair · 04-07-2014, 01:56 PM

The steering wheel was making progress, but we had to set it aside for other priorities...
Here is where it got to..

Remember, this is the first time we have tried anything like this!

The 4 panel cover stitched together, and tested to get the spoke positions right... trickier than it sound as the dark brown leather is stretchier than the cream!

After cutting it to size and shape, the cover was then folded and run thru the machine with a #25 needle and no thread to create matching holes..

Test wrap...

Starting at one spoke, we began to hand lace the cover... a bit erratic with the thread tightness to start with, but we made it better.

Almost done with the upper section...

Keyair · 04-07-2014, 02:02 PM

There is a lot going on outside of the Airstream...
I have been working (with help), on the Alfa... and I know its not Airstream progress, but will maybe explain my distraction....

More work completed.
Drivers side seat retrimmed.

Pass side seat back is next.
But you can see how much work it took to get to the above pic when I show you the start point...

Its a mess under there.

After grinding off the top layer of the original foam, started by adding a section of denser foam(yellow) to rebuild/mod the original foam edge to fit the new covers.
Then added the 3/8" pink foam over that.

My test fit of the cover tells me another layer is needed in some areas.
The passenger side seat base needed some TLC.

Rough paint and some surface rust.

Into the sandblaster it went... and an hour or so later...

I treated the pitted areas, with rust converter to be sure, and then sprayed a rust converting primer to seal it.

After a day to cure, I went ahead with the topcoat.

Keyair · 04-07-2014, 02:12 PM

Other stuff completed...
Parking Brake and Shift gaiters done with custom thread highlight to match the trim.

Interior floor underlay fitted.

Carpets cut and fitted, edged and highlight stitched.

Door trims...

Seat back trim before and after...
All completely new, wood and vinyl..

mayco · 04-07-2014, 02:12 PM

Man you do wonderful work! Good on ya.

Keyair · 04-07-2014, 02:24 PM

Thanks!
Truth is, the Alfa is good practice for the real fun stuff to come on the AS!

wxbuoy · 04-07-2014, 03:30 PM

Very nice! Wish I had 1/10th your skills!

Keyair · 04-07-2014, 03:35 PM

Quote:

Originally Posted by wxbuoy

Very nice! Wish I had 1/10th your skills!

Thanks Dave, but the truth is you do!
What you are doing to your MH is testimony of the skillset you already have, with more to come.
Some of the things I have done, and will do, are new to me... I just have, sometimes foolishly, a no fear attitude!

streamquest · 04-07-2014, 10:19 PM

Steve,

I have a question for you…...

Is there anything that you don't know how to do???

You could well be among the last of the great Renaissance Men. Beautiful work!

Charly

Keyair · 04-07-2014, 11:04 PM

Quote:

Originally Posted by streamquest

Steve,

I have a question for you…...

Is there anything that you don't know how to do???

You could well be among the last of the great Renaissance Men. Beautiful work!

Charly

Charly,
Its a compliment coming from you.
For the record, I can't sing and I can't dance.
Everything else, I will take a shot at!
There are a LOT of talented and driven people here on the Airforums.
Its amazing what a little drive can do!

shepherd57 · 04-08-2014, 05:51 PM

Keyair
Have you got a pattern for the steering wheel cover replacement it looks great. Mine has a spot on the top covered with tape, I would like to attempt to do the same on my wheel.

montreal · 04-09-2014, 04:24 PM

Amazing work Steve. IS that an Awl that you have used to stick the steering wheel?
Asked you a question about gearboxes in my post
D

Keyair · 04-09-2014, 04:43 PM

Thanks!
I used my sewing machine to punch the holes. By folding the cover across itself and running it thru the machine, the holes were punched evenly and symmetrically so the lacing holes line up.

Yes, I will post the dimensions when I get a min, but the diameter will depend on you leather stretchiness... if that is a word!

Seat #2 is done... Lot of foam work on this one to get it right...
Glue foam, cut, shape, test... repeat 3 times...
End result looks good tho!

Mockinbrd · 04-09-2014, 05:39 PM

Wow! Wow! Wow!
Beautiful! That looks DARN good!

Keyair · 05-03-2014, 11:56 AM

Thanks!

We are making progress, and as is the case, there are many skills and processes that will make the Airstream better once the Alfa is gone!

Here is one...
We needed to fabricate an exhaust heat shield for the Magnaflow SS exhaust system that runs hot and close to the drivers floor.
We rolled a piece of aluminum, folded the edges, and then I began looking for some heat insulation material.
My buddy then says... let me help you with that, as he is in that business... and here is what I ended up with!

He tells me its a fire retardant fiberglass/mica material and is good to 2000deg or so... I will get the full spec soon..
He said to protect it from oil absorption by adding a layer of foil on the engine side.

Anyway, I am thinking that this would be PERFECT to line the inside of the doghouse with!
The roll is 4' x 15', and I only used a 8" wide strip off one end!

And of course, the heat shield became a little test bed....

Aluminum must be polished and riveted!

Backside..

Test Mounted...

Interior is almost finished... Another step forward toward getting back to the Motorhome!

crazeevw · 05-04-2014, 12:13 AM

that would make a FINE 'toad' for the Airstream.....

Keyair · 05-04-2014, 11:24 AM

Yes it would Derek... But we need more space for our Dogs!

I got the info on the heat shield stuff... I think it will work well!

ZetexPlus® is woven from highly texturized continuous filament yarn and treated with a proprietary vermiculite-based coating. The coating allows heat to disperse evenly across the surface of the fabric, significantly boosting temperature rating and abrasion resistance. Newtex’s proprietary vermiculite coating has larger platelets and a greater percentage of solids than competitive coatings allowing for better coverage and superior heat dispersion. Our coating also features an organic adhesion promoter to improve the bond between the platelets and the fabric. The adhesion promoter reduces flaking and wear for a longer product life. It also improves the fabric’s resistance to moisture.
ZetexPlus® can withstand constant operating temperatures up to 1500°F (815°C) and peak temperatures up to 2000°F (1095°C).
ZetexPlus® is commonly used to fabricate protective gloves and mittens, blankets, covers, heat shields, insulation, and jacketing.

Keyair · 06-28-2014, 11:45 AM

Its been a while since I have been here.
Various health and other issue have kept me away from Airstream work, but it coming.
The Alfa work is almost done, and soon it will need little of my time, and energy.

As I said before, there are many parallels with the Airstream work ahead and its a nice test piece.
Excuse me if I share some of the things that have been done.

The Alfa's fuel tank was a mess inside...
Today's fuels attract and hold moisture, which leads to rust and varnish..
This is the result...

After cleaning and derusting LOTS, it was looking better, but it looked like there was some other kind of liner, so it needed more work.

The final fix was a tank liner from Red Kote.

It was poured in thru the various pipes to ensure complete coverage.

The excess is allowed to drain out, and the coating was left to dry for a week, after which I added a 2nd coat.

After that, the outside was refurbished to complete the job.

Next it was a TIG welded hard-top stand, that was painted to match the car.

And to finish the interior work, the trunk was paneled and carpeted.

Maybe 2 weeks more work, and then it back to Airstream stuff!

bkahler · 06-28-2014, 02:31 PM

Quote:

Originally Posted by Keyair

Its been a while since I have been here.......
................Maybe 2 weeks more work, and then it back to Airstream stuff!

...bout..time...

Brad
(who unfortunately hasn't really been doing anything of note on the Argosy either)

wxbuoy · 06-28-2014, 03:53 PM

Quote:

Originally Posted by bkahler

...bout..time...

Brad
(who unfortunately hasn't really been doing anything of note on the Argosy either)

Ditto!

Keyair · 09-18-2014, 12:06 PM

Now things are easing on the other project AND I am feeling a little better, I promised myself I would start doing some small things on the AS.

I have re-written my priority list... and this little job was on it.

Had a nice set of Mickey Thompson cast aluminum valve covers, and planned to powdercoat them, however, there was a problem with them.
Someone in the past hogged(more like chewed!) out the breather hole and they were too big for my PCV valve, or anything else. So they needed filling in before I redrill them to the correct size.

The aluminum filler needed to be thicker than any sheet I had... so upon looking about my shop, I found a damaged Honda Oil pan that was in my scrap pile.
Cut it up to get the flat section I wanted.

Which I cut and filed to fit the hole...

I had never TIG welded on cast aluminum before, but after fiddling with the setting a bit, I managed a reasonable job of it!

Grinding, and making it flat revealed a little porosity, but its solid and good penetration, which will be ok, as it will be hidden by the PCV valve grommet. Hopefully, with my settings correct the next one will come out better...

Hopefully, when #2 is done, I can finish prepping for powder!