'54 Flying Cloud - Complete Overhaul

[MarkR]

ouch, you must have been shocked.
I have detailed measurements of my 21' frame (and right now the frame and shell are separated (they remain friends, and I even think they have reconcilable differences (as opposed to irreconcilable) with some work of course) . . . So anyway if you need any measurements or photographs or ?, I'd be glad to help.

[NorCal Bambi]

I'll second the ouch on the frame. I'm afraid to look at mine. I know it will be bad. Thanks for the kudo. Everybody on the forum has kept me going as well. It's nice to think that I might pass a little of that on.
Don

[Cloud 9]

Yeah, I guess I should have known better when I saw the Washington License plate, but hey, blinded by aluminum. Any way here's a little more on what I've done so far.
After I removed the whole interior, I removed the lower interior panels. (I didn't remove all of the interior panels thinking that it wouldn't comprise the structural integrity of the shell as much. I plan on removing them for the rest of the interior refurb after I get the shell back on.) Then I attached cross bracing to the exposed ribs. 2X4's were attached perpendicular to the cross bracing down the length of the trailer. I attached some 2X4 scrap pieces to the bracing and used those as lifting points where I used a couple of bottle jacks to lift the shell up. All of the rivets around the bottom perimeter were drilled out and any remaining bolts goint through the channel were cut off. Once the shell was up I slid in two 4X4's that extended out past the shell 2 feet on each side.

More to come

Steve

[NorCal Bambi]

Cloud9, thanks for the pictures. I'll be watching every step of the way. My plan is to watch your progress to get me motivated to redo my 55 FC. I don't think I'll do much until next spring. So you should be well along by the time I go to work on mine. After working for 10 months on the restoration of our Bambi, I need to get some work done around the house. I'd like to repaint my truck also.
Don

[Cloud 9]

Alright, I knew would be too busy to post during the summer. But now things are winding down at work and I can get back on track.

After the shell was lifted the frame was pulled out and taken in to be welded. I wanted to do the welding myself but my wife wanted to have a "Professional" do it. Sooo... I took it to someone who came highly recommended and had all new crossmembers and outriggers welded on. I won't go in to the hassles of getting small town businesses to work on any type of schedule. Needless to say after 4 weeks of sitting at his shop the welding is completed and I get the frame back to my work area.

I started painting the frame using Eastwood rust encapsulating paint. Got all of the top and sides that I could reach easily painted so I flip the frame over to finish the job. As I'm doing that one of the new welds breaks! Further inspection of the frame shows partial penetration on almost all of the welds! Welder is called back and finally returns to fix the job after two weeks of angry calls and threats of a trip to small claims court!

So now I'm waiting for a little cooler weather to finish painting. I think I'll probably need more paint too. Two quarts just isn't quite enough.

Any way here are the rest of the pictures I have of the removal of the frame from the shell (It's always nice to have some helpful Rangers to do the heavy lifting ).

[Cloud 9]

Not all the pictures made it. I guess I'll have to sit down and figure the easiest way to upload pictures.

[NorCal Bambi]

Thanks for the new pictures. In your line of work the summer is probably work, work, work. One thing I've found when loading pictures is when all the pictures don't show up. Click on "manage attachments" again and reload more pictures. Sometimes it seems that it only likes to process three pictures at a time.
Don

[Cloud 9]

Thanks Don,

It does seem to be only taking three at a time. Here are the rest that I meant to post

Steve

[NorCal Bambi]

I started tearing some of the very rotten floor out of my trailer. Guess I should start a new thread on the 55. Sure like the shine of your shell. Do you have any more pictures of the original frame in its original condition?
Don

[Cloud 9]

Originally Posted by NorCal Bambi

I started tearing some of the very rotten floor out of my trailer. Guess I should start a new thread on the 55. Sure like the shine of your shell. Do you have any more pictures of the original frame in its original condition?
Don

Here are the other photos I have of the frame as we found it.

[uwe]

Someone got quite creative with the 2x4's. Better than crashing through the floor, I guess.
This obviously needs a fair amount of welding repairs. Might be worthwhile to consider a new frame altogether. You can build it right on top of the old one, using the old one for a template. Then, transfer the running gear over tot he new one and off you go.
I am suggesting a new frame because it seems that the main frame rails are severely weakened by rust.

[Cloud 9]

I don't know if I made it clear when I started this thread, but I'm farther along in the process than the pictures depict. I already have the frame repairs done (I kept the main frame rails, they weren't as bad as you might think.) and am in the process of painting it.

I have to catch everyone up on what I've done so far. So here it is in a nutshell:
1. Removed rotten floor and gutted interior
2. Removed lower interior panels and braced shell prior to removal
3. Separated shell from frame
4. Removed frame and replaced all crossmembers and outriggers (these members were replaced with 3" C channel about the same guage as the main frame rails)
5. Removed axle and springs from frame
6. Replaced all lug studs
7. Replacing both brake assemblies (currently in process)
8. Painting frame (using Eastwood rust encapsulating paint) and axle (Rustoleum)
9. I also welded in gray tank supports similar to what Uwe did, but I haven't completed the installation yet.

I'll post pictures of each step I've done where I have photos. (Didn't have a camera with me all of the time.)

Steve

[Cloud 9]

Sorry if I've repeated anything from previous posts.

From the Department of Redundancy Department

[NorCal Bambi]

I'd like to see pictures of your shell lifting. A description of your process would also be appreciated. Great to hear how much progress your making.
Don