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Old 11-24-2005, 08:10 AM   #1
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Skin Replacement 68 Safari

Last weekend Murray ( Creampuff) and I tackled the long overdue streetside skin replacement on his 1968 Safari. The sheet was damaged, and one of the vertical ribs was also bent by a minor accident the trailer had suffered. We're not going to elaborate how this happened, to protect the innocent.....
In any case, here the first pictures, of the trailer's damaged body.
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Old 11-24-2005, 08:30 AM   #2
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Skin removal

First, Murray cut a bunch of rivets with a chisel and putty knife, while I drilled out osme of the more critical ones, around the windows etc.
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Old 11-24-2005, 08:31 AM   #3
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Sheet gone!

Here are a few images of the partially undressed Safari.
Due to the graphic nature of these pictures, parental guidance is advised!
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Old 11-24-2005, 08:41 AM   #4
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Yiks - Airstream nudity on the forums........

Looks great so far........

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Old 11-24-2005, 08:43 AM   #5
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Surgery

We found that one of the vertical ribs had sustained some damage when Murray hit the wall with the trailer the second or third time, I forgot which time it happened...ooops, we were going to keep this classified information....ahem...in any case, a sister rib was fabricated, and carefully grafted onto the bent section of the original rib. We copied the curvature fom an existing, yet undamaged, rib.
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Old 11-24-2005, 08:47 AM   #6
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Rib repair

2 more pictures that got swallowed by cyberspace during the last post
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Old 11-24-2005, 08:53 AM   #7
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In the meantime, the old sheet was cleaned up for use as a template to cut the new metal.
We decided to use 032 Alclad, as the entire bottom of the sheet wraps in to form the lower rounded edge of the trailer. It joins the belly pan at about 4in under the trailer. 040 would have been a bear to bend.
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Old 11-24-2005, 08:57 AM   #8
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Cutting the new sheet after the pattern was transferred to it from the old sheet.
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Old 11-24-2005, 09:01 AM   #9
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Install/seal

The freshly cut sheet was first fitted, then trimmed in a few placs, and finally secured with clekos. Next time the Vulkem goes on after fitting and cutting the sheet, keeps people from looking like walking vulkem catridges.
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Old 11-24-2005, 09:06 AM   #10
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Next step was installing the sheet with Olympic rivets, applying yet more Vulkem here and there,and around each and every rivet hole. Each rivet got a small amount of Vulkem around the rivet shaft. We want no leaks!
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Old 11-24-2005, 09:12 AM   #11
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Cleanup time

Murray immediately got busy cleaning up the exces Vulkem around all the rivets and seams. He ended up using acetone and paper towels.
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Old 11-24-2005, 09:16 AM   #12
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Time to shave

Now, all the rivets got a close shave courtesy of a rivet shaver borrowed from Glyn. Thanks, Glyn!
The finished sheet installation looked very straight and clean. It got late, so we did not take pictures of the wrap procedure. But the job did get finished in one day, and we were both quite pleased with the outcome.
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Old 11-24-2005, 09:19 AM   #13
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No Drill Here!

btw., there are wires right underneath the skin, one should know where they run, and take note before drilling for new rivet holes.
Sorry, this photo is upside down.
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Old 11-24-2005, 09:42 AM   #14
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Nice work and great pics.
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