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Old 08-15-2015, 12:06 AM   #435
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Millertime's rear bathroom rot '76 Tradewind thread

Been over a month since my last update, got a good one!

A big thanks to Zep and to Larry B for their posts on interior metal endcaps, really helped a lot.

First I needed to make a patch in the rear endcap for an unneeded plumbing vent, my new layout only needs one.

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Old 08-15-2015, 12:14 AM   #436
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Next I cut the aluminum segments as outlined in Larry B's post "Aluminum Interior Endcap Segmented". I cut enough for both sides using a harbor freight electric metal shears, they worked great and cut nice straight lines.

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Next I took the panels in sets of 5, aligning the short and long edges on the side nearest the holes, and drilled holes .5 in from the edge 1.5 inches apart. This closely simulates the spacing on the exterior endcap. As you drill never skip putting in clecos!

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Old 08-15-2015, 12:19 AM   #437
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The endcap needs spacers to provide support for the dome as it takes shape. I could not find 1.75 inch foam so I bought 1 in and .75 in closed cell foam and glued them together in 3 in squares with contact cement. You will need about a half sheet of each for the front and back, quarter sheet for just one.

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Next I glued them to the endcap ceiling with spray contact cement at approx 7 in on center spacing.

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Old 08-15-2015, 12:25 AM   #438
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Finish the insulation with loose fiberglass I pulled off a roll.

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You start at an outer edge ensure you have about 1 in of overlap with the wall edge, align the short edge with the overhead panels and press it tight to the ceiling and drill a hole, cleco, drill, cleco, along the short edge.

The long edge works the same way.

Once it is secured, place your next panel, ensure your overlap is the same for all panels, cleco, drill, repeat. Make sure you press the panel right to the ceiling.

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Old 08-15-2015, 12:44 AM   #439
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Millertime's rear bathroom rot '76 Tradewind thread

Once you finish the 5th panel switch to the other side and repeat. Once you get to the center panel check your spacing, your left and right sides should be very close since you drilled them all together. Make any small adjustments on the 5th panel so that your center panel is dead center.

The center panel is riveted on both sides.

Ok here are some things I did different than others who have done this project.

1) I used 5/32 rivets, I just had way more black clecos. I had 100 and I still had to take a lot and move them forward.

2) Brace yourselves, I used 5/32 POP RIVETS. Yes I could have used Olympics, the expense and lack of a shaver dissuaded me. Yes I could have taken the whole thing down and bucked 350 or so rivets on each one. It was a lot of work just to get to this point and I am solo. So there you go, I used a HF pneumatic rivet gun and got those 350 rivets per endcap in quick and easy. The 5/32 pop rivets have a nice head size and actually look really good IMO.

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Rear, I trimmed it straight across and regretted it afterward though it looks fine. It caused a slight gap on the sides and I should have just left it and let it go under the screen frame like the front. Only trim where needed under the window frame trim to keep it out of view.

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Front endcap!

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Another photo before I put screen back in place.

This was a big project, albeit once I understood the process the front went much faster. Plan for 12-14 hours on your first one using this method if you are mildly handy. All you master aluminum artists out there be kind in your comments


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Old 08-15-2015, 09:31 AM   #440
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Nice work
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Old 08-15-2015, 10:03 AM   #441
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Matt,
Nice!!
Derf
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Old 08-15-2015, 10:40 AM   #442
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Nice job! Got any close up pics of the 5/32 pop rivets? Sounds way faster and cheaper.
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Old 08-17-2015, 10:29 AM   #443
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Airstream attaches interior skins with 1/8 pop rivets. Your 5/32 pop rivets will have a good head size, similar to the exterior solid rivets. Olympic rivets are tri fold design for assembling softer materials. They are one of the weakest rivets on the market. Your end cap has a dense rivet spacing, it looks plenty strong. I support your decision to use pop rivets over Olympic.

Your aluminum end cap looks great. What a lot of work! Thanks for the Trade Wind update.

David
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Old 08-17-2015, 08:56 PM   #444
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That looks great. Thanks for the tutorial. I'm not putting the plastic end caps back in also.
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Old 08-18-2015, 08:19 AM   #445
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Nice Job! Its good to see you are still plugging away at it.... you are an inspiration to me. I hope to reunite my frame and shell in the next two weeks but have followed your progress over the last year.
Mark
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Old 09-21-2015, 10:09 PM   #446
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Very impressed. What a huge undertaking. Keep up the great work.


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Old 09-23-2015, 09:14 PM   #447
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Thanks everybody! Mixter I will get you that photo. I am taking night classes Monday-Thursday this semester so the trailer is in hold till next year. In the meantime I am saving funds for a polish job and planning out the interior.

Cheers and munch on!


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Old 10-06-2015, 09:53 PM   #448
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Hey all, took the family out to San Onofre Campground in Camp Pendelton. Aluminum tent camping at it's best right on the beach!

Question for the group, I want to remake my wheel wells out of metal, was recommended to use 16 gauge steel. Any idea how to construct them? Square is fine no need for fancy complex angles. Might just hire a metal shop to make them if need be.


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