And so it begins.......

[Unka Jack]

Hello again, thought I'd update the work being done. As the saying goes, "The devil is in the details". I thought I could just cut and remount the plywood floor and be done with it. Then I got to thinking about all the little details that had to be done prior to laying down the floor and putting the belly pan segments back on. First was all the pre-wiring that had to be run through the frame. The brakes, breakaway switch, power supply for the electric jack that I plan to buy at a later date. then was the plumbing, with the tanks, connecting pipes and dump valves. Also the sensors for the tanks. I chose to go with the SeeLevel gauges.
here is the installation pics:

First cut the sensor to length with scissors.

[Unka Jack]

Next was to cut the tab identifying which tank it is.

[Unka Jack]

Finally remove the backing and apply to the cleaned tank side with a 1/4" top and bottom clearance. Be careful, you only get one shot. The sensors are to fragile too remove and reapply. With the sensors attached, just have to connect the wires. The beauty of this system, is that all the sensors are connected in parallel, only 2 wires.

[Unka Jack]

Here's a pic of the freshwater tank area with the new valves and applied sensor. The dark green on the tank is where I had to weld a large crack back together. Saved me the cost of a new tank! Welding plastic was quite easy. If anyone want more info let me know. I can document the repair of my end caps.

[Unka Jack]

And to catch up to today, I've cut the Plywood using the old ones as templates. I had to extrapolate some of the curves where the wood was rotted away. I happened to have a couple of quarts of "Bilgecoat" marine paint leftover, so I used them to paint the floor panels. Also used penetrating epoxy to seal the edges of the plywood. If the wood lasts another 40yrs, I wont care. I'll be 97!!! Somebody else can replace the floor again. Besides, I plan on keeping up on the seam maintenance. Also, I've removed the leaking vista windows, cleaned the frames, and will be reinstalling them using glazing tape.
As always, suggestions and questions are always appreciated.
Cheers,
Jack

[cwbiii]

Originally Posted by Unka Jack

Finally remove the backing and apply to the cleaned tank side with a 1/4" top and bottom clearance. Be careful, you only get one shot. The sensors are to fragile too remove and reapply. With the sensors attached, just have to connect the wires. The beauty of this system, is that all the sensors are connected in parallel, only 2 wires.

They recommend securing that wire real close to the sensor to avoid the wires from being pulled accidentally off of the sensors. That hot weld button on it is not very strong. I would have left a bit more wire on it and duct-taped it to the tank as stress relief... but that's me.

Chuck

[Unka Jack]

I did tape it after the pic was taken. I didn't like the strain on the wire myself. All the connections were with a double crimp and heat-shrink connectors. Also there was heat shrink tubing with adhesive lining applied. I don't like my wiring to come apart. Or get water into them.

[Unka Jack]

Another week gone. The floor is now bolted down with the wheel well liners repaired and installed.

[Unka Jack]

The wheel wells were "welded" using ABS rods and a "Plastic welder" from Harbor Freight. This one looks like a soldering iron with a triangular plate tip. There are other name brands out there, but for small jobs I couldn't justify the $170.00 to buy their kits. The results look rough, but I was using these as training before I tackled the ABS end caps. The welds appear to be as strong as the original plastic. I didn't really want to stress them to the breaking point and do them again.

[Unka Jack]

Went out today with my better half and ordered the vinyl flooring. Now just waiting for some more days off (with dry weather) so I can flip the frame and floor and rivet the belly pan back on between the rails. The wraps will come later.
Cheers,
Jack

[djarrett]

There are only a few complaints I could raise about Airstream and the quality, but for the life of me, I cannot determine why they didn't (and don't) galvanize their frames.

Most European Trailer ('schuze me ... Caravan) manufacturers do so.

Just wondering.

D

[Isuzusweet]

Originally Posted by nashrover

There are only a few complaints I could raise about Airstream and the quality, but for the life of me, I cannot determine why they didn't (and don't) galvanize their frames.

Most European Trailer ('schuze me ... Caravan) manufacturers do so.

Just wondering.

D

Or use Coosa for their floors.......

Great project with a lot of helpful info.....Keep up the good work.

Cheers
Tony

[Unka Jack]

Tony, thanks for the kind words. Feel free to stop by for a look see if you're down Niagara ways.
Cheers,
Jack

[Unka Jack]

Another week of work got in the way of working on the trailer, but I did get some things done. Since the shell is going back on soon it was time to fix the Vista windows. First up was removing the old, multiple layers of different types of sealant. Started by using some things I learned from some guys in the aviation industry.
These are sealant removing cutters, and bristle wheels. They fit into an air grinder alone or together.
I tried to get a video of them in action, but working with the tool in one hand, camera in the other while standing on a ladder made for some very bad video. I'll post a pic later so You can see the job these tools do.
The cutters are for thicker sealant. The wheels are for thinner sealant. Once most of the sealant is gone, just use a rag with your liquid of choice (varsol, acetone, xylene etc.) to wipe off the remainder. To do the exterior took about 10 min. per window.

[Unka Jack]

A note of caution, although the tools did not appear to remove the clearcoat, I cannot guarantee that they won't. Since I plan on removing the clearcoat later, I wasn't that concerned. Also, if there is grit in the compound, the grit may put fine marks on the metal. The tools themselves are designed to remove sealant from aircraft wings without damaging the wings themselves. Another caution if you hit the metal with the chuck of the die grinder it will scratch the metal!

[Unka Jack]

The radial bristle wheels can be used singly or stacked to about 5 deep. when used singly, they are very good at digging out the sealant between the flange, and the skin of the trailer. So when you reseal, you get a good bond between them without just adding to the old sealant. keeps it nice and pretty.
Cheers,
Jack

[Unka Jack]

Once the frames were cleaned, I used glazing tape to reinstall the glass. It's available at almost any glass shop. It never hardens, and any residue is quickly cleaned with varsol. I have the double windows with the "C" clamps. Placing the tape around the edge, then placing the glass in the frame. If you miss with the tape, it is self amalgamating. You can just cut small strips and work it back into itself with your fingers. I repeated the process with the inner lexan pane. The glazing tape comes in different thicknesses, you may have to use multiple layers so it fit with the clamps exerting a little pressure on the edges. Here is the final re installation of the vista windows. Note the clean outer edge of the frame (vs the one below) waiting for a new bead of sealant.

[Unka Jack]

The "Reunification" of Silver Roof is compleat!

Spent the last week finishing up the chassis, pre-wiring, putting most of the belly pan back on, pre-cutting the vinyl floor, all the little jobs that are so much easier without the shell on. Final flip of the chassis, put the axles back on and ready for the deed.
Today the boys came over to help. We repositioned the gantries. Then hoisted the shell, finally moved the chassis back under the shell.
The lowering of the shell went as smoothly as could be expected. One man on the hoists, one on either side watching the skins coming down and the last one watching to make sure the ribs were inside the channel.
We started at 9:39, we were done by noon.

Once again my thanks to the boys (none if which are under 50) Terry, Bryan and Alf without whom this would have been a lot harder!

[Unka Jack]

Now come the joy of replacing all those #://)@@(/;&#%*¥¥>## rivets that I had to drill out in the first place.

[Unka Jack]

Ps, the day was made even more enjoyable by the Avro Lancaster Bomber, out of the Hamilton Warplane Museum, doing a couple of flybys