And so it begins.......

[cwf]

Wow,,,, got some work there! Also try to kill that rot and seal it.

Check out "Git-Rot" or the System3 stuff!

[Unka Jack]

After Christmas, got working on stripping out the trailer. Everything came out slowly but undamaged. (At least no further damage by me) During the coldest Feb. on record. Began removing the inner skins. The mouse trails and tunnels were bad.



All cleaned up as best I can without spraying down the inside. (Its still below freezing some days)



The little red box is my 240V contractors heater, allows me to work during the winter.

[Unka Jack]

Was planning to scab in some floor sections and retrofit some grey water tanks. With that, the welding repairs, and having discussing it with my other half, looks like I'm going "the Full Monty". All in all, does not look too bad. It needs doing, but not too bad.

Here are the worst spots.







A PO's idea of a repair. He just cut out a piece of rough sawn hardwood and stuck it in.



For the record, the curbside vista window leaks like a sieve. The streetside vista not quite so bad but close.

[Minno]

Your walls look very very similar to ours! Taking off those inner skins can be a good thing. Gets rid of that musty odor too, along with replacing the floor in our case. We had quite the acorn stash in our walls when we took them off. It's definitely a process but well worth the time, we decided. Of course, we're almost done...

Kay

[J. Morgan]

Those mouse houses are a trip. They kinda give me the willies....

Strangely, I had no rodent infestation in my walls. I am happy about that...


1/2 Ton 4WD Truck, 72 Sovereign Hensley Arrow

[Unka Jack]

Well it's been a long week. Got lots done, but never as much as I wanted to. Things done, removed AC unit. Scraping off the butyl sealant was no fun. Seems like one of the PO's really liked the stuff even covered all the screws which then had to be removed using a putty knife. Set up my scaffolding giving me a good solid work platform.
Also removed the broken antenna while I was up there.

The next job was drilling out rivets, both Pop and Bucked, hundreds of them. On the sides of the TT I decided to leave the "wrap around" C channel attached to the floor, just drilling the rivets. Some rivets had to be cut using a hammer and stiff putty knife. I will remove the channels after the shell has been removed. On the ends of the TT I decided to leave the plain C channel attached to the shell. The bolts holding the channel to the floor were all rusted, so spent lots of time with the pneumatic cut-off wheel cutting off the bolts. When there wasn't enough room, I switched to the Dremel with a cut-off wheel. When all else failed, cold chisel and big hammer. I tried to avoids that as much as possible. The channel itself is in pretty good condition, and I want to reuse it. Also removed the battery compartment so the shell will sit flat on the ground.

Whenever I got too stiff, sore or tired, I worked on building my gantry's. Got them all finished today. Unfortunately today is also my last day off for a while. Its going to be another 2 weeks before I get enough time off to focus on the Airstream and get some extra manpower for the "liftoff".

[Unka Jack]

Lift off and separation successful!

My work crew showed up on time, and the lift went as smooth as expected. There were the usual few hangups as I was expecting. Even my wife was surprised that the was no damage or rude words. My thanks to Bryan, Terry and Alf who came over to help manhandle the gantries into place and lift the shell. Also, my thanks to all the posters on the forum who's sage advice made this a smooth operation.
Now comes more disassembly.

[cwf]

Unka...
Beautiful! Now, may I kindly recommend you move the "gantrys ".... Were wind to tip one, we would all be sad for you.

[Unka Jack]

Thanks for the tip, gantries are down. Had another nice day so started taking off the floor ( saving the old ones for templates ). Most of the frame is solid with only mild to moderate surface rust. The outriggers are what I had seen earlier with no surprises. Unfortunately, there is a section of main rail that the top flange was rusted away. Not worried about the cross supports, I will most likely just weld in replacements. My decision to make, is do I just cut off at good metal and weld on a new section of rail. Or, do I weld in a reinforcing plate along the rail and weld on a top flange. I was always taught that a welded joint is never as strong as forged metal. Any frame experts out there want to weigh in?

[Unka Jack]

The other topic I would like to kick around is redoing the waste tanks.
I'm already planning to put in 2 grey water tanks up near the axles. After removing the black water tank it was found to be excessively broken near the flange to the point where I wouldn't trust any repair welds. The toilet I'm planning on using is a marine toilet that I have left over from a previous project. It comes with a built in macerator pump allowing me to pump the discharge to the black wart tank. My thought is to put the tank just behind the grey water tanks and run a 3" discharge line out to the rear bumper. The valve would be an electrical one with access for service/repair under the planned street side bed. Anybody have thoughts, concerns or suggestions?

[cwf]

I'm thinking the steel that decomposed is from a lousy batch ... or repeatedly dampened. I have never had a weld break. The steel tends to break on the edge of the weld. Probably due to stressors... such as fatigue..which was already in the original steel. I have found that matching the type of steel used in the repair and using the correct welding steel.... and temperature control.

One of the things you can do is to heat the areas prior to welding... don't quench. If welding big pieces, pre-heat... but that is a whole art form....

So, in as few words as possible:
1- using cribbing, carefully support the frame.
2- cut away the 'bad' areas using a reciprocating saw (to minimize heat distortion) leaving appropriate locations for rewelding and adding of 'doublers'
3- carefully create replacement pieces.
4- As you weld in new pieces, add 'doublers'... and add them across the frame, in close to the same place as the repair, from Street to Curb side. This will stiffen the frame 'equally' ... yet still allow for healthy 'flexibility'.
5- cover with rust preventative of choice.

[Unka Jack]

Frame is coming together. After a week of wire brushing, grinding and cutting. Spent the day with my father in law welding pieces back on. First was the section of rotted rail. I was able to get a 6' length of matching steel cut and formed at a local metal shop for $45..
Many thanks to Ron Barry who after many years of retirement came out to help. He was only supposed to supervise and coach my welding, but he was having so much fun I didn't have the heart to take the welding gun away. Even in his 80's he enjoyed welding again.
The more I cleaned the frame. The more damage I found. So this week I'm back to the metal shop to get more custom angle bent. I'm also getting them to bend up a new box for the black tank.,
This project is really beginning to nickel and dime me! But in the end it will be worth it.

[Unka Jack]

Forgot to upload this pic. It was prior to cutting and welding.

[Unka Jack]

Got home after shift this morning and flipped the frame. With the gantries and chain hoists, I was able to do it myself.
Sitting back on the blocks.


Joy oh joy, more grinding, wire brushing and welding.

[cwf]

Nice work!!! Wish we were closer to help...

[NavyCorpsman]

I really admire your effort and attention to detail. Very nice.

[Unka Jack]

YEEEHAAAWWW,
Last of the frame welding repairs are done
Somebody finally took a pic of me at work.

Here is one of the new grey water bays ready to go.

All done.


Now onto the clean prep and paint phase.

[Unka Jack]

It was a wet week last week but I managed to get the frame cleaned, acid etched and POR 15'd. When it was raining I broke out the rivet gun and bucking bar and made a new pan for the black tank. ( The old one rusted out) Never having used a rivet gun and bucking bar before, was surprised how easy and quick it was. Before this I had just ever used a hammer for buck rivets. Never many or pretty afterwards but sufficient at the time. Here's some detail shots of using the gun and bucking bar. Now I'm just waiting on the black tank from VTS. Then I change hats again and become a plumber before the new floor goes on.
My lovely wife has given me until mid July to reunite the parts. We have a wedding in the backyard in September so I have to be available for yard work until then.
Enjoy the pics.
Ps any good suggestions from those who have gone before me are always welcome...

[Unka Jack]

Got the grey tanks from VTS, perfect fit in the bays.While waiting for the black tank to be shipped, went ahead and started roughing in the plumbing.

[Unka Jack]

Today I also went and got the plywood for the replacement floor. As soon as the last of the tanks are in and plumbing connected, I will start installing the floor. If the weather holds, I should be on track for the "Reunification" before mid July. My lovely wife says I better be. If not, I will be spending my vacation playing catch-up.