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Old 11-22-2014, 09:12 PM   #1
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End Caps

We are remodeling our 76 Airstream. We are wanting ideas and pictures for what people are doing in WOOD with their plastic end cap areas. Ours is cracked and we would love to put wood in like a fan or starburst pattern.

If you have done this and can lend advice I would sure appreciate it.

Thanks
Tammie


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Old 11-22-2014, 09:18 PM   #2
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Originally Posted by tweetie1966 View Post
We are remodeling our 76 Airstream. We are wanting ideas and pictures for what people are doing in WOOD with their plastic end cap areas. Ours is cracked and we would love to put wood in like a fan or starburst pattern.

If you have done this and can lend advice I would sure appreciate it.

Thanks
Tammie


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Tammie.

Headliners can easily be repaired and then painted, so that it looks perfect.

Use caution if you decide to replace the headliner, since it is also a part of the monocoque construction.

Andy
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Old 11-22-2014, 10:01 PM   #3
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I will be watching this thread.
Would love to get rid of the plastic interior end caps.


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Old 11-22-2014, 10:31 PM   #4
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bunch of people have done this kind of work

Search for links - here's one

http://www.airforums.com/forums/f417...od-101290.html
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Old 11-22-2014, 10:47 PM   #5
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Look at J. Morgan's posts

http://www.airforums.com/forums/f46/...ls-127555.html
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Old 11-23-2014, 06:01 AM   #6
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End Caps

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It isn't hard once a person gets started, and it is super firm. It is in no way fragile.

1/2 Ton 4WD Truck, 72 Sovereign Hensley Arrow
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Old 11-23-2014, 06:48 PM   #7
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I know you said wood, but... Colin Hyde is developing an aluminum end caps that is quite dramatic. Also, check out the Timeless Travel Trailers website. You might get some ideas there. J morgan makes it sound easy, but I think a person would have to be a pretty good woodworker to make one. Compound curves in wood is way beyond me. Maybe there is a wooden canoe or boat person in your area that could help.

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Old 11-23-2014, 07:13 PM   #8
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End Caps

I had never done any woodworking before this project, it really was pretty easy, because, well, I work hard to find the easy way of doing things.

All that was really needed was to push the rough cut piece into place and mark the edge with a pencil.

Cut the curve, and then work the final fit with a good sander with 80 grit paper. The final fit took some time, but it would have taken less time had I not been so intent on making a tight fit. In the end I didn't need a tight fit because the stringers cover the gap anyway.

It was intimidating at first, but it wasn't hard, the front end cap probably took the best part of a couple of days. It took longer to trim around the front two quarter windows.

(I am by no means worthy to be called a woodworker, I am just persistent)

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Old 11-24-2014, 05:02 AM   #9
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Very nice J Morgan. Maybe I'm too intimidated about making pie shaped wood skins. Some of us are very good craftsman in the garage, and some of us are rather clumsy. I'm in the latter category! I struggled making bulkhead walls in my rear bathroom!

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Old 11-24-2014, 06:12 AM   #10
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Originally Posted by dbj216 View Post
I know you said wood, but... Colin Hyde is developing an aluminum end caps that is quite dramatic. Also, check out the Timeless Travel Trailers website. You might get some ideas there. J morgan makes it sound easy, but I think a person would have to be a pretty good woodworker to make one. Compound curves in wood is way beyond me. Maybe there is a wooden canoe or boat person in your area that could help.

David.
Yeah, the development is completed & we now have stock. There are options to suit Airstream's from the 50's through current production (except wide bodies)
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Old 11-24-2014, 09:14 AM   #11
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End Caps

David, don't go thinking that making a bulkhead wall is that much easier than doing what I did in the front of the trailer.

Making a bulkhead fit the wall can be a challenge that has a learning curve.




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Old 11-24-2014, 07:07 PM   #12
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No pun intended on leaning "curve". Like the compound curves of an end cap. The shower walls in the back of my Trade Wind were a challenge for me, especially getting the aluminum U channel extrusion to lay flat against the molded fiberglass.

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Old 04-22-2015, 01:15 PM   #13
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Wood paneling

These are 1/8" baltic birch ply panels trimmed with 1" x 1/16" aluminum flat bar. Time consuming but very happy with the results so far.
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Old 04-23-2015, 08:22 AM   #14
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It looks great. I have some appreciation of the difficulty in making these birch panels. The aluminum "seam covers" are a great idea.

Very nice craftsmanship indeed. I only dream about having that skill level.

David
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Old 04-23-2015, 08:39 AM   #15
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My skills are pretty basic. If I can do it, so can you.
I have a good source for the flat bar trim. It is very flexible and easy to line up with panel seams. Once it is cut and drilled, I attached it to the end cap with #8 x 1/2" sheet metal screws spaced every 3-4". Then cut posterboard templates for each "pie piece" and mark the screws heads with a pen and cut the template to fit. Then tape to the birch ply and cut panel with a jigsaw. Sand, stain/varnish, then removed one trim strip, fit up panel and reattach trim. Repeat 12 times :-)
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Old 04-23-2015, 09:54 AM   #16
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These are 1/8" baltic birch ply panels trimmed with 1" x 1/16" aluminum flat bar. Time consuming but very happy with the results so far.
BambiTex,
Is the only attachment for your system the screws? Or did you use a little adhesive on the backs of the ply, too?
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Old 04-23-2015, 09:56 AM   #17
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No need for adhesive. Once you bend them into place, they stay put on their own.
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Old 04-23-2015, 04:14 PM   #18
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These are 1/8" baltic birch ply panels trimmed with 1" x 1/16" aluminum flat bar. Time consuming but very happy with the results so far.
Thats a great look! Keep the pics coming!
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Old 04-27-2015, 06:38 AM   #19
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Panels

OK. Here is the finished product.
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Old 04-27-2015, 06:46 AM   #20
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Very Nice!
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