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Old 02-20-2014, 11:34 AM   #1
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1959 22' Caravanner
Tampa , Florida
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Replacement Belly Pan Panel Layout

Has anyone worked out an efficient aluminum panel layout for 22ft +/- A/S?

I'm looking at 48" roll stock cut to order vs. 4x8 or 4x12 precut panels.
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Old 02-20-2014, 01:10 PM   #2
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1960 24' Tradewind
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I went parallel w/the trailer length. Unfortunately (2) 48" wide sheets isn't quite wide enough, so I added a center 6" wide piece the full length of the trailer. I overlapped an inch for the seams so it basically added 4" to the overall width or 100" total. I pop riveted the whole thing together.

I thought about it for awhile, probably laid out 5 or 6 versions on paper and then went w/this idea - it wasn't perfect, and it was a hassle managing the giant sheets (wish I could have flipped the frame upside down).

Anyway, that's what I did, w/what I could get or already had.
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File Type: pdf 60TradewindBelly.pdf (24.9 KB, 51 views)
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Old 02-20-2014, 01:22 PM   #3
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I used 4' x 12' sheets cut to fit around the perimeter and semi truck on a roll .032" aluminum down the centre of the chassis (about 56" or so). That way I got the good exterior qualities and nice one piece central sections.
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Old 02-20-2014, 03:09 PM   #4
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I have a 21' '73 Globetrotter that I replaced the bellypan on. I used 4' x 12' sheets. My center sections were ~56" wide, so started by cutting those center sections from the long dimension of my sheets. Then I did the side sections with what was left. I didn't end up with a lot of scrap, and the side and center sections overlap on the frame main rails, so there aren't obvious patches or seams. Have a look at post 9 of the following to see how all the pieces fit together:

http://www.airforums.com/forums/f36/...on-115765.html
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Old 02-20-2014, 05:29 PM   #5
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I found that 4'x8' sheets were easier to work with than larger pieces. If you are interested, here is the layout I used.
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Old 02-20-2014, 08:32 PM   #6
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Love this forum...amazing, thanks! Here's what I'm thinking: The chassis is 8ft wide so I ordered 4 x 10 sheets (from ARCO Metals @ $46/sheet. I ordered (7) 10ft sheets. I plan on installing them in a side-to-side orientation starting from the back. Using a 4 inch lap, (6) sheets will cover 22'-4", probably just short of what I will need including wraps and folds, so I'll skip the axle and keep setting sheets sideways to the front. Once all sheets are in place, I'll come back with a 2ft strip of the 7th sheet and close things up at the axle.

Will a 10 ft sheet span transverse across the chassis and leave enough to make the wrap and fold at the floor plate/rub rail?
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Old 02-20-2014, 08:37 PM   #7
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You do realize you're going to have to post some pictures of your trailer, don't you?

Especially since it's a Caravanner!

-steve
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Old 02-20-2014, 08:37 PM   #8
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Quote:
Originally Posted by MarkR View Post
I went parallel w/the trailer length. Unfortunately (2) 48" wide sheets isn't quite wide enough, so I added a center 6" wide piece the full length of the trailer. I overlapped an inch for the seams so it basically added 4" to the overall width or 100" total. I pop riveted the whole thing together.

I thought about it for awhile, probably laid out 5 or 6 versions on paper and then went w/this idea - it wasn't perfect, and it was a hassle managing the giant sheets (wish I could have flipped the frame upside down).

Anyway, that's what I did, w/what I could get or already had.
Impressive! Nice work!
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Old 02-20-2014, 08:40 PM   #9
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Quote:
Originally Posted by pbearsailor View Post
You do realize you're going to have to post some pictures of your trailer, don't you?

Especially since it's a Caravanner!

-steve
I'll get on that. Problem is, all we've been doing is stripping the interior paint, and once that gets started, no one wants to get anywhere near a camera. I need to get one of my nosy, err, curious neighbors to take some pics. BTW: The stripping is brutal, but man does the interior look nice so far...can't wait to buff it!
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Old 02-20-2014, 09:05 PM   #10
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I used 48" wide panels and had them sheared to 56", then I installed the 56" dimension across the trailer starting at the front. At each joint (every 48") I installed a 2-1/2" 25ga galvanized steel stud and riveted it to the frame, then butted the panels together and riveted them to the stud (I painted the studs with bed liner paint first, thinking this would eliminate or at least greatly slow galvanic corrosion).
I found this size of panel relatively easy to work with, and I can take off a single panel for inspection purposes if necessary. I'm happy with this arrangement so far.
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Old 02-20-2014, 11:23 PM   #11
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Quote:
Originally Posted by JimCat2000 View Post
L
Will a 10 ft sheet span transverse across the chassis and leave enough to make the wrap and fold at the floor plate/rub rail?
If you mean side to side and enough to curve up and tie into the C-Channel, then yes 10' (120") would be more than enough - my 60 needed 100" or 8'-4" . . .

actually I just re-read that you're saying your frame is 8' wide . . . mine is 7'-4" (88") and 100" wide material was plenty. I thought 59's were essentially the same as 60's (?).
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Old 02-22-2014, 10:40 AM   #12
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You bring up a good point. I need to actually measure it, because I was just going by a dimensional chart I found on-line.
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