ok guys. first and foremost, i am NO EXPERT! in fact, this '59 traveller is my first trailer! my grandparents used to always take me out for the summer in theirs, and i knew i had to get one. i've always wanted to restore something cool, so here we go. i decided to do a complete shell-off frame up restoration. it's the only way, in my opinion, and if you saw my frame, you'd agree! i tell ya, i have learned more with a pry bar and a saw in my airstream than anything i've read so far. i know a lot of you guys have done the complete shell-off restoration, and i wanted to run my plan by you all for feedback to hopefully steer me clear of any uncharted dangers!
here's my plan (i've already made it through the first couple of steps, but i'll put them in anyway for others).
1) remove complete interior cabinets, furniture... down to the bare shell.
2) remove 4 pieces of bannana moulding
3) drill out rivets connecting the belly pan to the body & drop pan
4) remove sub-floor (mine was so rotten, it practically pulled out by hand)
5) after i removed the subfloor, i had to use a cut-off disk to remove all the rusted bolts that held the floor on. (this is where i am with my '59 at the moment)
6) cut off all bolts from the shell to the frame.
7) build temporary bracing for the shell, once it's lifted (i plan to use x-bracing both vertically and laterally, with additional support along the body line of each side).
8) drill out rivets holding wheel-wells to body shell, and remove wells.
9) lift shell (with several friends and a jack?) above the frame and set on temporary saw horses.
10) pull frame. weld in replacement cross-members and outriggers, if neded (mine needs 3 of each). i also plan on welding the nuts to the shell that hold the shell on, so i don't have to access them once i put the belly pan on. sandblast the frame, epoxy prime, and final coat with silver.
11) replace axle and suspension with new.
12) install grey and black-water tanks in the frame if they are below the floor (this is all guess. my trailer was completely gutted when i got it, so i'm not 100% certain how the plumbing went in.)
13) cut wood floors using old as patterns (if only i COULD!) i'm going to have to guestimate mine. i'm planning on making a pattern BEFORE i lift the shell to make sure the pattern is correct.
14) reinstall wheel wells and splash guards.
15) install weather-proof insulation over the top of the frame rails
16) install new floor with new elevator bolts (i want to find an alternative to plywood. i don't want this thing ever rotting again!)
17) install center belly-pan piece first, then the 4 corner pieces, moulded to the shape of the floor.
18) drop shell back on, and install bolts into the frame. also, install wood screws between frame bolts.
19) line everyghing up, seal and rivet-away.
now the fun parts begin!
seriously, though, is there anything wrong with the order i have listed above? also, if anyone has any tips or what-not, i'd love to hear them! i'm planning on digging in saturday morning and HOPEFULLY getting the shell off, and the frame ready to weld.
thanks a million for any advice!
jordan
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