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Old 09-06-2015, 06:50 AM   #155
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1997 30' Excella
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Rivet Failure is not an option!

Thanks everyone for the comments! I made an interesting observation:
One can share a project like this "live" or after you succeed, taking pictures and notes on the way.
The live sharing adds an element of elevated skill levels and a more thoughtful process, as in "ok, guys, really pay attention to this detail, it can hurt you down the road"
So, in a way, I credit you as audience in helping me succeed on a superior level.
I did not include the rivet setting/shaving process. You can view some details in an old tutorial of mine from 2002 below.
You may find it interesting that the shaved rivet in the tutorial is the rivet image used next to our names on the forum, just in gold.
REMEMBER NOT TO USE OLYMPIC RIVETS WITH WASHERS, THEY WILL FAIL!!

http://www.airforums.com/forums/f381...tml#post711305
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Old 09-10-2015, 02:52 AM   #156
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Riveting

Hey Peter, i just saw the old pictures you posted to explain the Olympic rivets.
CONGRATES to your skills!
It is amazing to see your knowledge about our riveted beauties!!!!
I wish, the "fools" from "Airstream4you" in Germany were at least half that helpfull, then you are!
I am for sure a "good" Airstream re-modeler inside the coaches, i rebuilded my "Bangles" (345classic) in the original colours and design, but without the (massive!) fails from the factory, but i was allways afraid to touch her from outside.
Now i bought all the tools and rivets, i found on german EBAY an old compartmentdoor from a trailer.
It was cutten out with some body panel, so i can try and learn on this piece, before i touch the bidy of "Bangles".
I want to install this door (A formaly Batterie compartment, fully flat!) in the Curbside under the awning, to create an "outside entertainment center", or backwards as an "outside shower" for the dog, after a beachday.
I am still unable to post pictures here, so i could share (proudly!), what i have done inside till today.
Have fun, keep on "Airstreaming"😃😃
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Old 09-12-2015, 02:44 PM   #157
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Just ran a foot short of the decal I still had from a previous restoration. Had to come up with something to fill the gap...
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Old 09-12-2015, 02:48 PM   #158
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Quote:
Originally Posted by PeterH-Airstreamer View Post
here is a breakdown of the cost to replace the three upper rear panels:
300 Rivets, 4 tubes of Vulkem, 3 panels shipped directly from Airstream
$ 1,700.- incl shipping
Time spent 38 hrs x $0.00=$0

Lets compare that to a written estimate from a Pro Airstream shop
Parts: 2,250.-
Labor: 4,600 ( incidentally the hours quoted are 40 !!!!!!!)
Misc Labor/Materials 180.- (replace and RR driving lights)
Total Estimate $ 7,030.-

7,030.- (shops estimate)
less 1,700 (my material cost)
=5,330 divided by 38 (the hours it took me)
=140.27 my unofficial hourly rate to have a lot of fun, share it all with you guys AND do a better job !!!!!!
something to really think about

You did a GREAT job! Looks absolutely perfect! I admire your skills. Well done!
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Old 09-19-2015, 07:44 PM   #159
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Todays challenge was:
Broken exhaust stud extraction without removing the exhaust manifold
1 broken stud
1 sleeve to guide the left handed drill bit
1 left handed drill bit (to increase the chance of the stud drilling itself out)

The idea is to drill a pilot hole using the sleeve guide to stay on center. Then run the engine until hot and start drilling with the left handed drill bit. In many cases it will pull the broken stud.
The left drill bit did not succeed in removing the broken stud, but an easy out did!! Success!
Can't post pictures ATM, but will later
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Old 09-19-2015, 08:39 PM   #160
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Well done.... I have failed at that job before, so will be interested to see your method, especially how your sleeve works.

Are you doing anything to stop the new stud from breaking? Is it the rearmost on the right side?
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Old 09-19-2015, 08:56 PM   #161
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Quote:
Originally Posted by Punch View Post
Well done.... I have failed at that job before, so will be interested to see your method, especially how your sleeve works.

Are you doing anything to stop the new stud from breaking? Is it the rearmost on the right side?
2nd from rear was the one broken flush with cylinder head, 3rd from rear was also broken, but flush with manifold. I am using grade 8 bolts instead of using studs. 20lbs of torque is not very much and I believe anyone could easily over-torque those.
First I carefully checked if the bolt was centered with the manifold hole. Then my good friend Mercurycharlie made me a perfectly fitting sleeve for the manifold hole to keep the drill on center. He told me that it most cases the left handed drill bits will extract the broken thread.
check out Charlies website to see the cool stuff he does
The Home of Mercury Charlie
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Old 09-20-2015, 04:48 AM   #162
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broken stud, sleeve and left hand drill bit
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Old 09-20-2015, 06:29 AM   #163
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That sleeve is a simple idea that never occurred to me. Useful information that I hope I won't have to use again.

This seems to be a 454-only and motorhome-only problem, doesn't it? I have had motorhomes with other engines and 454's in other vehicles and never seen it in either.
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Old 09-20-2015, 04:22 PM   #164
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We always put brass washer under the rear two. Then we supported the exhaust manifold close to engine.. Next, we used "flex" exhaust piping and had good support of exhaust. That kept the extra weight off the rear of the manifold. Also no more gasket blowouts.
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Old 09-24-2015, 04:32 PM   #165
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Today, I used my 15 year old ramps again, Martin .
We both could fit under there
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Old 09-24-2015, 04:45 PM   #166
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Close up of the GM Motor label. It is 030 over, main and rods 010
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Old 09-24-2015, 05:13 PM   #167
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Quote:
Originally Posted by PeterH-Airstreamer View Post
Today, I used my 15 year old ramps again, Martin .
We both could fit under there
Peter, the design looks good

I'll be making some of those for my Argosy once it's in the shop.
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Old 09-24-2015, 07:33 PM   #168
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Quote:
Originally Posted by PeterH-Airstreamer View Post
Today, I used my 15 year old ramps again, Martin .
We both could fit under there
I have taken notes, and tried to scale some dimensions from the photo, seems like a job for this weekend!
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