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Old 03-27-2017, 07:13 AM   #101
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Originally Posted by DDickey View Post
I think it's going to turn out well, but the front end cap is killing me. I decided not to replace the rear end cap, but clean the old one instead. I'm re-riveting it today and hope to get it up this week. The front, however, has been a bear. I originally cut the old fiberglass end cap into 13 segments and used it for a pattern. That didn't work out and I ruined a sheet of Alclad. My next strategy is to use the rear endcap segments as a pattern and transfer it to the front. The two end caps have slightly different shapes, but I think it will work *crossing fingers*

I used the old panels as patterns and have the new pieces cut. I think everything else is going to go in just fine, my biggest concern is to not crease the ceiling panel. The reason I decided to replace most of the panels is because the trailer had been remodeled and there were a ton of rivet holes in all the wrong places.

Either way you go it's so. much. work.
If your patterns don't work out. I have my front and rear caps apart and I can trace you the pieces on brown paper. Just let me know.
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Old 03-28-2017, 06:50 AM   #102
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Patterns

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Originally Posted by islandtrader View Post
If your patterns don't work out. I have my front and rear caps apart and I can trace you the pieces on brown paper. Just let me know.
Hey islandtrader,

That would be fantastic, and I'd be happy to pay you for it. Since I've decided to reuse the old panels in the rear I just need the front
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Old 03-28-2017, 07:09 AM   #103
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Hey islandtrader,

That would be fantastic, and I'd be happy to pay you for it. Since I've decided to reuse the old panels in the rear I just need the front
Send me a pm with your address...and I will trace them out for you.
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Old 03-29-2017, 11:21 AM   #104
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Last Weekend's Labor

Here's the (almost) finished rear end cap from last weekend. These are the old skins, stripped, polished and re-riveted. I was shocked at how much better Citristrip worked than Aircraft Stripper, but Citristrip is certainly the way to go (still a ton of work). I also learned that DiamondBrite Truck Box Polish is the bomb. I tried about a half a dozen different polishes, and DiamondBrite with a Harbor Freight polisher and pads worked the best. I buck riveted it on the ground then lifted it back in place and most of the old holes lined up. Sweet.

The front is another story. Lucy came with a fiberglass front end cap, which I hate, and my first attempt to fabricate a 13 panel Alclad endcap was a failure. Islandtrader has his cap apart and he's graciously going to trace it and send me the patterns *crossing my fingers that it works*
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Old 03-30-2017, 07:35 AM   #105
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This is the point where I'm questioning my sanity

I suppose there comes a point in every shell-off where you go, 'what the hell have I done? Am I doomed to work on this thing until I die?' I think I'm officially there. My wife is after me for all the things I've neglected on the house. Our friends think I've become an obsessed recluse. Even the dog has a curious look in his eye. Occasionally, 'Maggie May' comes on the radio and it has become my song to Lucy:

Wake up Maggie I think I got something to say to you
It's late September and I really should be back at school
I know I keep you amused but I feel I'm being used
Oh Maggie I couldn't have tried any more
You lured me away from home just to save you from being alone
You stole my heart and that's what really hurt

The obsession continues...
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Old 03-30-2017, 08:29 PM   #106
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I suppose there comes a point in every shell-off where you go, 'what the hell have I done? Am I doomed to work on this thing until I die?' I think I'm officially there.

The obsession continues...
Oh cheer up my last boat project was 5 years. Now I'm doing this airstream and thinking in 2 years maybe I'll be done. Not so bad...haha
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Old 03-30-2017, 10:05 PM   #107
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I'm going on 9 years! Your doing great
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Old 03-30-2017, 10:39 PM   #108
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Five years for a boat?

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Oh cheer up my last boat project was 5 years. Now I'm doing this airstream and thinking in 2 years maybe I'll be done. Not so bad...haha
What kind of boat?
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Old 03-31-2017, 07:54 AM   #109
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Sounds like my house

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I'm going on 9 years! Your doing great
We bought a house on the lake 16 years ago and I began remodeling it. It's not done
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Old 03-31-2017, 08:31 AM   #110
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What kind of boat?
1964 Seacraft Off Shore

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Old 03-31-2017, 03:38 PM   #111
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Wow

Great job!
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Old 04-01-2017, 07:33 PM   #112
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Rear endcap complete

That was about 24 hours worth of work, now onto the daunting front endcap...
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Old 04-03-2017, 07:21 AM   #113
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That was about 24 hours worth of work, now onto the daunting front endcap...
Patterns on the way...piece of cake
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Old 04-03-2017, 07:55 AM   #114
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Thank you so much!

I'll let you know how it works out, and I owe you one!
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Old 04-23-2017, 10:51 AM   #115
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Front Endcap Half Way Done

The process is: measure, cut, sand exposed edge on table sander, tack in place, check for fit, check again, drill (start in the middle and do it carefully, it can get wonky), cleco, drill some more, check for fit, remove all clecos, clean the drill shavings, trim hidden edge tight to drill holes, reinstall, cleco, Olympic rivet, check for fit, move to the next piece.

Once the entire endocarp is complete I'll shave the Olympics, drop the cap to the floor and insulate, then permanently install it.

So. Much. Labor. But once they're done I feel like I'll be able to get the rest of the inner skins installed in a day. I feel like I'm on the downhill slope.
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Old 04-23-2017, 04:46 PM   #116
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Once the entire endocarp is complete I'll shave the Olympics, drop the cap to the floor and insulate, then permanently install it.
Why Olympics? Just use a few plane pop rivets...then when you drop the skin, you can buck rivet them all.

Just a thought.

Did the patterns work?
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Old 04-24-2017, 10:03 AM   #117
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The patterns are great!

I'm using Olympics on the front because I'm building it in place so I can ensure fit. I bucked the rear but had to build it on the ground. Since it was the old skins it fit like a champ
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Old 04-26-2017, 09:47 AM   #118
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Front cap is 97% complete

I've finally got the front cap done with much thanks to Islandtrader for tracing his endcap and sending the patterns to me. I built this cap differently than the rear since these are new skins. For the rear cap I deconstructed it, cleaned it, and put it back together on the floor using buck rivets. It took it's old shape quite nicely, and even the holes to hang it matched back up. Since the front is all new skins I wasn't confident that it would take the proper shape, so I built it piece-by-piece in the air using Olympic rivets starting with the center. I'm glad I did because I had to pull and stretch the third and fourth panels from the center on each side in order to get the right shape. I found that a quarter of an inch here and there makes a big difference in the shape of the cap, and the only way I could make it work was to lay it out, check it, adjust it, check it again, bend it, pull it, manhandle it into shape, then button it down. It was slow, tedious work, but I'm happy with the results.

The second pic is the cap dropped on the floor so I can insulate the front of the trailer. I didn't want to insulate, then drill, because the bit messes up the insulation. The completed cap is light, but flimsy, it shouldn't be a problem to hang. I'm looking forward to finishing the front cap so I can get after skinning the rest of the interior!
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Old 04-26-2017, 09:17 PM   #119
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Old 04-30-2017, 07:24 AM   #120
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Front Done

Still need to shave the Olympics and polish
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