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Old 05-24-2015, 10:02 PM   #29
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1969 31' Sovereign
Auburn , Washington
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Looking great I wish I had a place big enough to do a shell off like this.
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Old 06-08-2015, 09:19 PM   #30
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1960 33' Custom
Saskatoon , Saskatchewan
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chassis weekend II

I bit more progress this weekend. Bolting up the suspension felt pretty good. Outriggers are up next.
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Old 06-29-2015, 08:27 PM   #31
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1960 33' Custom
Saskatoon , Saskatchewan
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out with the old, in with the new

A busy weekend; day nine saw the build completed. Kind of sad to see most of the old chassis prepped for recycling; weirdly we noticed the axles were solid 2 1/4" steel bar!

Next up is the weigh scale followed by a thorough degrease, etch and multiple paint coats.

I found it interesting to see just how much steel shifts around during a build and I'm glad I didn't try this out on my own.

It was also my first stab at building axles and brakes but so far so good.

We welded the Andersen WD brackets up and I think she's going to look pretty tidy with new paint.
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Old 07-04-2015, 09:36 PM   #32
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The last chassis post...

I know chassis shots are an acquired taste but I've got to include some with paint.

I tried out the Andersen hitch and it felt good and silent. I also snagged some BAL X chocks which I'm liking a lot and add another layer of security.

Plenty of tire space and decent unobstructed clearance.

Next up is a little bit of top coat then it's plywood time at last

I wore a respirator all day long which had the side benefit of filtering out all the smoke from Saskatchewans forest fires which would have kept me indoors.
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Old 07-05-2015, 09:03 AM   #33
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Wow that looks great
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Old 07-05-2015, 09:57 AM   #34
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Great thread! It looks like you're going to have a wonderful, quality trailer when you're finished!
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Old 07-05-2015, 11:06 AM   #35
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1981 31' Excella II
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Looks good, how much did you beef up the frame compared to the old one? You will find some detractors here who think beefing up the frame is not a good idea but I think they are wrong.

Perry
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Old 07-05-2015, 12:06 PM   #36
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Thanks all. I went only half crazy with the beefing up. 6" x 2" tube all around but 3/16" wall thickness for the mail rails and crossmembers at the axle-less axles, 1/8" wall for all other crossmembers and outriggers. A little 1/4" plate for the axle reinforcement gussets and 1/8" 2" x 2" angle for a couple of intermediate crossmembers, bumper tabs and wheel well supports. It's heavier but retains some flex too.
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Old 07-05-2015, 11:30 PM   #37
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1959 26' Overlander
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Looks sweet! Keep posting the detailed photos of the progress.
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Old 07-11-2015, 07:04 PM   #38
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nice project

I know i'll muss change the frame too ... so I like to see what you have done.
What kind of MIG welding machine did you use & witch gas did you use?
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Old 07-11-2015, 08:18 PM   #39
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It's the father in laws welding set up and is based around a massive generator and a DC lincoln mig. We mostly used the mig with CO2 but it got windy on and off so there was some stick used too. If my wife had more confidence in my welding a massive chassis as my first project I was going to get a Miller 211 and run C25 but that'll be next time
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Old 07-17-2015, 09:26 PM   #40
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Plywood

I saw a post on another thread a while back where the poster said something along the lines of "spend days researching every insulation material and end up with pink fibreglass". Well I researched flooring material endlessly and chose HDO. Which was then made unavailable in my area. I researched options again and couldn't decide between Monopan, Coosa, SpaceAgeMaterials Tough board or aluminum skinned ply. In the end I snapped and bought FormPly. Super cheap, no voids that I could find and one side phenolic impregnated paper. $400 rather than $3000 so I don't mind a little extra prep work.

Today I spend 8 hours cutting the 8 boards and dry fitting them. Other than making a nice little router jig that cut perfect arcs only to find that Airstream didn't and just copying their "shape" instead it all went smoothly.

I test fitted one wheel well and although it looks a little silly with stock 15" rims and undersized tires I hoping it'll do the job.

Next up is prepping the floor for install....
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Old 07-24-2015, 01:15 PM   #41
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1963 26' Overlander
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Wow that looks great. I didn't realize until just now that you'd sold your Overlander and had a new project. Suffice to say, I'm subscribed. Good luck!

-Marcus
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Old 07-24-2015, 09:16 PM   #42
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yup, sold but still local. The new owners are putting a ton of miles on the Overlander and should be down in Texas next month and then Florida before coming back home . I on the other hand will be spending the next couple of years or so getting this bad boy travel ready.

This week I had an OCD defining moment as I was Bondo'ing any defects under the floor, before base coat, before top coat and before rubberized undercoating.

I also picked up some C channel I'd had bent up; I paid a few dollars to get it all made up in 8' lengths.

Lastly I'd tracked down 5052 H32 in .032' 5' x 10' too but when I went to pick it up it became all too clear that ham fisted delivery muppets had ruined my plan. I'm now torn between a belly pan skinned in 4' x 10' sheets or going to .050" in 5' x 10's which is apparently more muppet resistant. I'm thinking smaller sheets right now for ease of dropping sections but thought I'd mull it over.
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