Thread Tools Search this Thread Display Modes
Old 06-12-2019, 10:02 AM   #1
New Member
Winnipeg , MB
Join Date: Jun 2019
Posts: 4
1975 Excella 500 Frame Repair and Improvements

Hi Everyone, new to posting here but I have been using the forum as a resource for a couple of weeks now.

My girlfriend and I are working towards renovating a 1975 Excella 500 from the ground up and we have just finished most of the gutting.

Now onto the frame. Many of the outriggers have rusted through and need replacement. There is also substantial damage to the main frame pictured below.

First, the outriggers, I have a little bit of scrap metal available to me and was thing about fabricating my own replacements. The problem is I dont know much about the strength of steel and its welds. Below are some images of my design for the outriggers I could fabricate. Basically the orange plate would be welded into two 1 1/2" x 1 1/2" x 1/4" steel angles. Then I would weld on two additional 1" x 1" x 3/16" steel angles for additional support and weld surface to the frame. I've found most of my outriggers have rotted out where they were welded to the frame, simply because they a very thin gauge steel at this connection. I think I can achieve the bend by cutting off a length of angle and using a metal bender, or taking a piece of flat bar instead, bending it to the angle and then welding it into the steel angle on the bottom support.

So, any advice? Is this overkill or have I made a mistake in my understanding?

Now the frame repair, as you can see from above, there is a small section that is rough shape, inside the channel there is also a lot of flaked rust. I am hoping two doubler plates will make suffice to reinforce this section. Can anyone advise on what the minimum gauge of this steel should be for this repair? I was initially thinking it should run 1 1/2' in each direction past the damage

Lastly, I wanted to add in some rectangular tubing throughout the frame to add some rigidity. I've watched some youtube videos and it seems a lot of people have been doing this. At the end of the day, I just want to reinforce this frame so that it will be strong enough to support the added weight of some 3/4" millwork panels when we get back to putting it together.

Ok, I think thats enough for now. Sorry for the long first post, im a little out of my depth with this metal work and want to make sure I do it right!
Attached Thumbnails
Click image for larger version

Name:	20190611_200935.jpg
Views:	25
Size:	416.4 KB
ID:	343121   Click image for larger version

Name:	20190611_200959.jpg
Views:	27
Size:	264.8 KB
ID:	343122  

Click image for larger version

Name:	20190611_201026.jpg
Views:	31
Size:	313.8 KB
ID:	343123   Click image for larger version

Name:	Frame.png
Views:	20
Size:	76.7 KB
ID:	343124  

Click image for larger version

Name:	Outrigger3.png
Views:	21
Size:	12.0 KB
ID:	343125   Click image for larger version

Name:	Outrigger2.png
Views:	22
Size:	29.3 KB
ID:	343126  

Click image for larger version

Name:	Outrigger.png
Views:	24
Size:	14.7 KB
ID:	343127  
Class is offline   Reply With Quote

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
Thread Tools Search this Thread
Search this Thread:

Advanced Search
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off

Similar Threads
Thread Thread Starter Forum Replies Last Post
1977 Excella 500 Coastal Camper :: 1977 Airstream Excella 500 Excella77 Airstream Registry Discussions 0 08-23-2014 02:18 PM
Excella vs Excella II vs Excella 500 vs Excella 1000 ElCamino Man Trailer Values 5 03-21-2013 02:32 PM
Replacing parts and making improvements don't stop in RV life Randall Airstream "In the News" 2 08-09-2006 10:08 AM

Featured Campgrounds

Reviews provided by


This website is not affiliated with or endorsed by the Airstream, Inc. or any of its affiliates. Airstream is a registered trademark of Airstream Inc. All rights reserved. Airstream trademark used under license to Social Knowledge LLC.

Copyright 2002- Social Knowledge, LLC All Rights Reserved.

All times are GMT -6. The time now is 12:04 PM.

Powered by vBulletin® Version 3.8.8 Beta 1
Copyright ©2000 - 2019, Jelsoft Enterprises Ltd.