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Old 09-08-2010, 03:57 PM   #29
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1976 31' Sovereign
Sandpoint , Idaho
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Wabbiteer, thanks for the details on POR-15. I've got to order some soon! :-)

Darrell, that is good information... where did you manage to find C channel to use? Salvage? Hard to imagine you can still buy it. I'm less worried about the weight difference and more concerned about structural matters. Had you said the height difference would cause problems, I'd have done something from below to help make a more rigid floor... the thoughts crossed my mind when I was working on it the other night.
Thanks, Pete
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Old 09-08-2010, 04:49 PM   #30
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Pete C channel is still available from any A/S dealer like Inalnd RV or Out OF Doors Mart. They only carry the C channel that goes along the sides of the trailer. It is the double C channel for lack of a better term. If you need to replace the channel that goes around the curved front or back you have to cut off the section that wraps around the floor sheeting. Some people have made their own also.
Do some measurements and see what difference 1/4" floor thickness would make to shell alignment. the front and rear c channels would have to be changed from their current location on the shell to match the side channels and sit on the new thicker floor.
For your vent pipes you can either cut them in half at a location that would be hidden and use a rubber coupler to reattach or remove the vent covers on the roof and slide the pipes up to remove them from the tank flanges. I cut mine.
How are you coming with the shell off plan?
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Old 09-09-2010, 11:44 AM   #31
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1978 31' Excella 500
Tuttle , Oklahoma
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Pete,
I bought the C channel from a local RV repair shop that is an authorized A/S repair shop. The original part number listed in the manual had been changed but he was able to find the replacement number.
I only replaced the curved section in the rear, the straight sections forward of that were okay.
On my trailer the straight sections are not the double C section, they do not enclose the plywood but just sit on top. The original rear curved section was not the double C section either.
They show no sign of being modified so I assume it was original.
The owner of the repair shop said he never knows what to expect when tearing apart the older rigs because of so many differences from rig to rig.
Darrell
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Old 09-09-2010, 01:55 PM   #32
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1972 31' Sovereign
Dade City , Florida
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Hey Guys,
This is my first time posting. I really enjoyed reading your articles. Great information. I have a 1972 31' that I am just starting. I think I will go with the 3/4" as well. Seems like the best bet.
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Old 09-15-2010, 06:19 PM   #33
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1976 31' Sovereign
Sandpoint , Idaho
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Its been a week or so since my last update. Things slowed down a bit. Had to get the gardens in and finish cutting, splitting and stacking firewood for the winter. But... I have been able to get an hour or so every other night to hack away at the project. I've got the lower panesl off of the the rear end and just have to pull a few from the front.


One of my front lower windows looks like trouble. There seems to be an excess of chalking or something similar along the bottom of the frame. Looks to me like someone at the factory was trying to cover an error.





Guess I'll worry about that when I get the frame and floor fixed up.

Thinking about the next big step of removing the shell. Maybe someone can confirm this for me... I need to cut off all of those 'elevator' bolts off, below the flooring before I can try to lift the shell. I don't want to remove any of the revits that join the skin to the channel that runs along the bottom of the frame... right?

Been wondering how I'll actually lift the shell once I have it free of the frame and floor. Since I have this in the barn, and the rafters are about 14 feet above the floor, I imagine I can rig 6 2x6 boards standing next to the shell in pairs on either side of the shell, vertically between the rafters and the floor. Maybe about 12 inches away from the shell. Then I think I can tie the top end to the rafter with two bolts just to keep them from moving at all. Then, I can evantually run another beam between each set of vertical 2x6 boards to support the shell off of the frame. I'm sure a short piece of 2x6 running from the floor up about 36 inches to support the cross member that is beneath the shell, will hold the weight at that one point. I'm looking for something that will be firm and can remain in place for up to 6 months. It will likely be that long before I'm ready to reattach the shell to the floor/frame.

Does any of that make sense? See any fatal error in my logic?

I'll dig around the forum tonight to see if I can find any discussion describing details of actually lifting the shell off of the frame.

I've been working late at night to keep my assistent out of the insulation dust... its bad enough on me and my dust mask.



More updates once I make any significant progress.
Pete
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Old 09-15-2010, 06:35 PM   #34
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1976 31' Sovereign
Sandpoint , Idaho
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By the way, those side, lower panels of alum. were hard to work with because they were so long. The port side lower panel was 24 feet long!! I rolled them up into rolls about 36 inches in diameter and tied them up to keep them that way, just to handle them alone. Must have taken 4 men just to put them into position at the factory.

Talked my brother the other night about the alum. material. He said it was standard aircraft alum. just like he used to work with in the Air Force as an airframe mechanic. He even knows how to buck rivets! Too bad he lives on the east coast...
Pete
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Old 09-15-2010, 08:36 PM   #35
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Shell Removal

Pete to remove the shell from the frame/floor combo you do have to remove all the elevator bolts holding the shell to the floor. There are also two larger bolts in front and two bolts in rear that are through the floor/C channel into the main frame rails.
There are two hold down plates one front and one rear. they are L shaped with the long edge riveted to the shell which must be drilled out to release the shell. Look for two rows of rivets in the front about a foot up from the floor and the back rivets are into the C channel.
Ther are actually two types of channel. The C channel that is curved aroune the front and back end caps sit on top of the floor and can be removed with the shell.
The C channel along the sides of the trailer is different. It is a double C channel, one horizontal and one vertical and it is a one piece channel. The vertical C has the inner panels and the outer skins riveted to it. The horizontal C is wraped around the edge of the floor sheets. This channel can not be removed with the shell. You will have to drill out all the rivets holding the exterior skins to it and inside you will have to drill out the rivets holding the ribs to the channel as well. This channel can only be removed once the shell is out of the way and the channel can be removed horizontally from the floor sheets.
I have attached a picture of a small section of this double channel so you can understand what I am talking about.
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Old 09-15-2010, 08:58 PM   #36
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Winston Salem , North Carolina
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Hi,

I thought the floor was either 5/8 or 3/4.
When or should I ask why did AS use 1/2" plywood??
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Old 09-15-2010, 09:11 PM   #37
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Shell support

Pete your plans to support the shell sound good.
You will have to build support or cribbing inside the shell to support and strenghten the shell once it is off the floor/frame. I used 8 pieces of 2x6 from side to side attached to the ribs. Here are the locations.
1) Forward edge of rear end cap
2) Just in front of bedroom windows
3) at the rear of the wheel wells
4) in the middle of the wheel wells
5) at the front of the wheel wells
6) at the rear of the entry door and the rear of the roadside living room windows
7) at the front of the entry door and in the middle of the roadside windows
8) rearward of the front end cap
This bracing is also attached together front to back mimicking the main frame rails. it is also attached at the end caps with a vertical 2x6 on an angle from the center of the bracing to above the windows attached to the ribs.
One problem I had is the outer skins around the end caps extend below the C channel so any horizontal supports meant to hold the shell in place had to be shimmed to keep the suppots from touching the skins. I used 4x4's as horizontal supports and a small piece of 2x4 as a shim placed between the 4x4's and the C channel.
I used 4 4x4's as supports, 2 of them at the end caps and 2 spaced equally between them. Well almost equally. The horizontals are attached at cribbing points 1/3/5/8.
Points 3 and 5 are attached with a small piece of 2x6's from the cribbing down to the 4x4's. The outer skins just float free at these points.
Points 1 and 8 are also attached this way and also have the 2x4 sitting on the C channel.
A little tip mark the location of your floor/frame on the floor of the barn so that when you are ready to put the shell back on you can line it up exactly. If you block the frame to the ground you can use bottle jacks betwwen the floor of the trailer and the cribbing to lift the shell up. Lift it front to back a few inches at a time until it is high enough to put yuor horizontals under the shell. make sure you leave enough room for the wheel wells to clear when you roll out the frame/floor.
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Old 09-15-2010, 09:18 PM   #38
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Greg my 73 was 3/4" and petes 76 was 1/2" or 5/8" so some time between 73 and 76 they changed. Probably to save weight and cut production costs. Today they use OSB ( oriented strand board) also known as chipboard. If it gets wet and it will it just swells up and falls apart. There was a post a while back showing what happened to a piece of plywood left out in the rain. It curled up and all the laminated strips seperated. I used marine grade plywood and some of my cut outs were left out in the rain and showed no sign of deformation or swelling and seperation. IMHO marine ply is worth the money. I also used a special paint on my floor to totally seal the wood. This paint is used to make aquariums and is guaranteed to be 100% waterproof. It actually is liquid rubber. My floor will never rot again.
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Old 09-15-2010, 11:11 PM   #39
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1976 31' Sovereign
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Wasagachris,

Thanks for the info on the cribbing. I'm surprised to learn 2x6 lumber was necessary for the internal bracing. I was expecting to get away with just 1x2s. But, much better safe than sorry.

That photo of the double C channel was exactly what I was picturing from your written description. But I'm glad you shared.

I actually made what felt like good progress tonight. I have removed all of the remaining lower panels on the inside. I also bagged up all of the insulation behind all of those panels. Tomorrow after work I'll clean out the work area again and get start on finding all of those bolts you described.

I saw the steel piece along the rear inside. Looks like pain to work with. I also noticed that it looks like the rear light fixtures were leaking. I can see water marks on the inside.

I'll post some pictures tomorrow, after I clean things up and locate the bolts.

Oh, I was thinking about this earlier as I was bagging that insulation. What is the best tool to cut off those bolts? I'm guessing I'll want to do so from beneath.
Thanks,
Pete
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Old 09-15-2010, 11:41 PM   #40
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Actually Pete I just clamped on to them with vise grips from above and bent them back and forth until they snapped off. I tried a grinder but that took a long time and sent sparks flying everywhere. I had to grind off the large bolts to the main frame rails they were too large to snap. You will also find several small screws securing the channel to the floor. If they are in good shape they should turn out or just grind off the heads. I'll try to get you good pics of the cribbing in the morning. I won't be doing much as we are expecting a heavy rain. I was planning on applying the metal etch to the new frame and painting with POR-15 on Friday. More Delays.
If you pull out one of the taillight cans you can see that the can itself is what seals the opening to the taillight housing. A/S then installs the inner plastic housing and seals it up with Vulkem and hopes all the water that leaks past the cans will leak back out. Piss poor design. BTW the taillight housings are riveted from the inside with pop rivets. They are hard to find behind all that vulkem.
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Old 09-16-2010, 11:45 AM   #41
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Pete check out post #14 on my thread for pictures of the cribbing. They are a little dark but you can see what I did for support.
http://www.airforums.com/forums/f36/...ins-67532.html
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Old 09-19-2010, 09:44 PM   #42
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1976 31' Sovereign
Sandpoint , Idaho
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Slow progress & several questions I need to answer

Hi there,

Got to spend about 5 hours on the project today. It was raining hard all day so I spent my time cleaning up the current mess and then starting on removing bolts and screws from the 'C' channel. The five bolts at the rear end came off easily. Four of them actually screwed off and one broke off. The three at the front came off with a little more work. One broke off as I tried to turn it with a 9/16th socket. The others came off with a little work with a cold chisel.

During a break in the action I took a close look at the 'C' channel along the sides. It seems to be the same stuff used as horizontal braces further up the interior of the shell. I didn't notice it at first but clearly it is the same material. The 'horizontal' part of that combined 'C' channel is sized for 1/2 inch plywood.

Several questions come to mind tonight:

Question 1: Do I need to remove the inside wheel well covers before lifting the shell? I have the outer covers off and I took a look today but it isn't obvious how to remove the inner covers.

Question 2: If steel and alum. against each other cause corrosion problems, why aren't they more careful to avoid contact? The very front exterior panel has a stell backing for mounting the drive light plug. Seems a bit of double laying of alum. would be just as effective and avoid the problem with dissimilar metals.

Question 3: How does stainless steel do with alum.? Does it still cause corrosion problems?

Question 4: As I was looking at the 'C' channel, assuming all of the bolts through the 'C' channel have been removed, I still I couldn't figure out the best way to lift the shell. Seems I'd have to spread the shell at the base to pull it away from the plywood. However, that doesn't feel right. Certainly can't do that if I have all my cribbing in place. Will I have to cut the existing plywood in half to get it out? I'm fully expecting to use it for a template for the replacement decking so I don't want to be destructive.

Question 5: Rivets... Are the original rivets known as the "olympic" rivets I've read about? I'm thinking the original rivets have a solid head that doesn't need to be 'shaved' like others. I noticed today that the rivets on the very front panel, where the trailer lights socket is mounted, have a wire center showing. Looks like that panel might have been removed and replaced at some time in the past. Someday I'll be replacing rivets on the shell and I'd like them to look like the factory installed rivets. So what type will I be using?

Sorry for all the questions... got on a roll as I'm thinking about the remaining work.

I'm likely to have to delay actually trying to lift the shell for a while. I've got to leave for a week business trip to Orlando next Sunday and then in 4 weeks I'll be off for month long business trip to Saudi Arabia ... but on a lighter note I went to an estate sale yesterday and scored a trailer mounted Lincwelder 225 rig for $100. I was the only person interested in it. Learned later from a friend of the family that it is suppposed to run well. I haven't had time to play with it yet but it is under cover next to the barn as soon as I find some time.

Pete
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