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Old 05-04-2019, 04:43 PM   #1
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2002 30' Classic S/O
Melbourne Beach , Florida
Join Date: Nov 2013
Posts: 3,661
Sofa Replacement Project - 2002 Classic 30

Thanks to blueloue69 for the suggestion and Ditter for some details I am now underway with my sofa replacement project.

Before Picture:

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The sofa is out:
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The sofa is gone (Thanks, Gerry and Roxanne):
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The new one is ordered:
https://www.recpro.com/recpro-charle...-with-console/

Lots left to do:
1. Figure out where to put the 12V distribution panel and converter
2. Clean up the wiring mess, including relocating the slideout controller to get it out of the area for the new built-in end table/cabinet where the power panel will likely go.
3. Design and build the roadside end table/cabinet and the extension to the curbside chair storage/flip-up table base.
4. Wait for delivery - the color I wanted wasn't available from stock. Shipping in early June.
5. Install sofa
6. and finally, Go Camping and enjoy it!

I'll post some more pictures are progress is made.

Al
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"You cannot reason someone out of a position they have not been reasoned into"

Al, K5TAN and Missy, N4RGO
2002 Classic 30 Slideout
S/OS #004
2013 Dodge 2500 Laramie 4x4 Megacab Cummins
2001 Safari 25 RB Twin (Gone, but not forgotten)
WBCCI 1322, TAC FL-39, AIR 82265

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Old 09-10-2019, 06:27 PM   #2
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2002 30' Classic S/O
Melbourne Beach , Florida
Join Date: Nov 2013
Posts: 3,661
Not much progress.....

Well, the loveseat arrived but life got in the way. First getting a new floor in the trailer, then a hip replacement surgery and PT rehab, and then a hurricane, but I'm getting close to starting the project.

Here's a picture of the loveseat:
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It is temporarily in our great room until I can get the trailer to the house to rework the power wiring and install it.

I ended up with an extra so I have an unused one posted in the classifieds.

Al
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"You cannot reason someone out of a position they have not been reasoned into"

Al, K5TAN and Missy, N4RGO
2002 Classic 30 Slideout
S/OS #004
2013 Dodge 2500 Laramie 4x4 Megacab Cummins
2001 Safari 25 RB Twin (Gone, but not forgotten)
WBCCI 1322, TAC FL-39, AIR 82265

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Old 09-23-2019, 10:15 AM   #3
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2002 30' Classic S/O
Melbourne Beach , Florida
Join Date: Nov 2013
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Finally some progress!

Life finally allowed me to make some progress. Good thing, we are supposed to leave 10/3 for a month on the road. While this post is about replacing the sofa with a recliner loveseat, you can also get a sample of our new floor. It is Mannington Adura Rigid vinyl plank.

Here's the before picture on the "wiring loom" behind the sofa:

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To be fair, I added the two red/black pairs for ham radio and CB power and the white duplex cable to power the disc brake actuator. The wall wart is supplying 12VDC to the circuit with the AC so I can run it while working in the trailer. All other 12VDC is off. The rest is as I found it. Apparently Airstream re-uses designs for cabling to cut costs as the wire harnesses are clearly not designed for each trailer. There are numerous instances of excess cable just being stuffed out of the way.

Here's the converter and power distribution panel box with some wiring disconnected:

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The power distribution panel, associated wiring and converter were in a box under the roadside end of the original sofa. I had to move it and rearrange the wiring to minimize the needed rework. I moved a ground buss bar to the back wall. I'm still deciding what to do with the power bussbar. I'm moving the distribution panel and converter to the roadside end of the new loveseat and will build a custom cabinet to sit on top of it for storage. I had to splice all the wires running to the distribution panel in order to move it. I cut them back in the middle so the original color would still be connected to the panel, not that it would do any good. My wiring bears no relationship to the diagram in my manual. There is a sticker on the door to the panel. It is different from both the manual and the actual wiring. At least it is a good depiction of the circuit breakers. I may re-connect everything so at least the circuit numbers would be right, or I may just figure out what all the circuits are and make a new label. Speaking of that, I figured out why there was a breaker in the floor of the box. Apparently one of the breakers failed and someone wired around it. I was upset until I figured out why. The breakers are all riveted to the plastic sub-panel and then the buss bars are mounted under the nuts on the breakers. To replace a breaker all the buss bars have to be removed (9 nuts and several wires) and then the rivets have to be drilled out. I guess I would have wired around it too, but I may take a shot at fixing it with a breaker mount which allows each individual breaker to be removed.

Test fit of the curbside seat of the recliner loveseat showing the cleaned up wiring loom:

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Lots left to do, including making a piece of furniture.

Al
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"You cannot reason someone out of a position they have not been reasoned into"

Al, K5TAN and Missy, N4RGO
2002 Classic 30 Slideout
S/OS #004
2013 Dodge 2500 Laramie 4x4 Megacab Cummins
2001 Safari 25 RB Twin (Gone, but not forgotten)
WBCCI 1322, TAC FL-39, AIR 82265

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Old 09-27-2019, 06:52 PM   #4
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2002 30' Classic S/O
Melbourne Beach , Florida
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More Progress!

I replaced the old Parallax 7355 one-stage converter with an Outback 60A unit. I cleaned up all the wiring and moved the power distribution panel over against the roadside wall. As a part of this move I put the long ground buss bar on the front wall, and relocated the umbilical junction box to the center of the front wall. I had to splice in about 8" of wire to most of the load lines. At the same time I re-organized the breaker panel to agree with the foil-cal on the door to the panel.

Here are pictures of the cleaned up wiring and the loveseat in place. I will be making a cabinet to sit on top of the power box to replace the storage lost from under the sofa.

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Al
__________________

"You cannot reason someone out of a position they have not been reasoned into"

Al, K5TAN and Missy, N4RGO
2002 Classic 30 Slideout
S/OS #004
2013 Dodge 2500 Laramie 4x4 Megacab Cummins
2001 Safari 25 RB Twin (Gone, but not forgotten)
WBCCI 1322, TAC FL-39, AIR 82265

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Old 09-27-2019, 07:28 PM   #5
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2008 30' Classic S/O
Hampton Beach , New Hampshire
Join Date: Jan 2017
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Sofa Upgrade

Al and Missy,

Looking great...nice job! We'll miss you at Slider II.

Tom - S/OS #025
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Old 10-08-2019, 06:47 PM   #6
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Almost Done

Added a base behind the power panel to support a combination storage cabinet/end table. It is screwed to the power box at the rear and both are screwed to the floor all screws are in the same plank space so as not to restrict the movement of the floating floor.

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I built a cabinet to go on top. It goes back into the curve of the front wall. Missy stained and finished it, and lined it with foam and covered the complete interior with headliner material.

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The top is almost finished. After fitting it I will make the final placement of the recliner loveseat and mount it loosely to the floor, again to preserve the movement of the floating floor.

Al
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"You cannot reason someone out of a position they have not been reasoned into"

Al, K5TAN and Missy, N4RGO
2002 Classic 30 Slideout
S/OS #004
2013 Dodge 2500 Laramie 4x4 Megacab Cummins
2001 Safari 25 RB Twin (Gone, but not forgotten)
WBCCI 1322, TAC FL-39, AIR 82265

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Old 10-09-2019, 02:17 PM   #7
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2002 30' Classic S/O
Melbourne Beach , Florida
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Finally Finished!

The cabinet/table top is on. I used cabinet door catches to hold it in place. I'm concerned they may not be strong enough to hold the top in place if the trailer bounces too much so I'm going to find stronger ones or add a z-bar at the rear and a magnetic kid-proof lock like I use on troublesome drawers at the front.

The recliners are bolted to the floor with 1/4" lag screws at the front just tight enough to keep them in place.

Here are a couple of pictures:

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Al
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"You cannot reason someone out of a position they have not been reasoned into"

Al, K5TAN and Missy, N4RGO
2002 Classic 30 Slideout
S/OS #004
2013 Dodge 2500 Laramie 4x4 Megacab Cummins
2001 Safari 25 RB Twin (Gone, but not forgotten)
WBCCI 1322, TAC FL-39, AIR 82265

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Old 10-09-2019, 07:00 PM   #8
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2008 30' Classic S/O
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Really nice looking Al...you guys will enjoy that for many years! Kudos!!!



Tom - S/OS #025
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Old 10-09-2019, 07:52 PM   #9
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Melbourne Beach , Florida
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Thanks Tom. The recliners are soooooo much more comfortable than the original sofa.

Al
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"You cannot reason someone out of a position they have not been reasoned into"

Al, K5TAN and Missy, N4RGO
2002 Classic 30 Slideout
S/OS #004
2013 Dodge 2500 Laramie 4x4 Megacab Cummins
2001 Safari 25 RB Twin (Gone, but not forgotten)
WBCCI 1322, TAC FL-39, AIR 82265

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Old 10-09-2019, 11:18 PM   #10
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1980 24' Caravelle
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what a great job, have a great time on your travels. kurt
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