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Old 10-17-2009, 09:26 AM   #71
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Not sure how this thread got by me for so long. So, happy that I found it and you are taking the time to share with all of us. Fantastic job you are doing, very inspiring with your great ideas and workmanship. THANK YOU!
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Old 10-17-2009, 12:33 PM   #72
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Quote:
Originally Posted by byamcaravanner View Post
Hank,

Look back to some of the early posts... there are LOTS of structural pictures. If you would like to see them closer up you can click on the thumbnails... if you would like to get even closer, try right clicking on the enlarged photo and select "save as" from the menu. This will allow you to use you photo viewer to zoom in as far as you like.

Make sure when you get to doing yours you post a lot of photos. Threads like this are invaluable to all of us.
Thanks for the advice, but the download jpg file size is only 128 KB (on the one image I downloaded), and the quality of the zoomed image (to my eyes, at least) isn't all that good.

I do promise to post photos when I have something to show. At this stage, all I have done is gut the interior of my 1956 Flying Cloud!
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Old 10-18-2009, 07:55 AM   #73
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Beautiful work. A lot to look at as I restore my 55 Flying Cloud.
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Old 10-19-2009, 07:10 AM   #74
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Thanks for all the recent compliments everyone.

I haven't had time to do any more work, but this winter will be the big push to finish the dinette. Right now I'm too busy getting next year's firewood in. We burn about 15 cords every year heating the house, the barn, and our hot water year round. No more heating oil!

Takes me a couple of months out of the fall to get that much out of the woods, bucked, split, and stacked. And of course I have to move last year's wood and this year's wood way to many times to think about.

Regarding the structural work, please go through the thread again, the photos are there. I've tried to show structural shots every time before I added any skins. And this is a very important part of the work. I've really tried to keep the weight down by using very light but sound structures, mostly 1x2 softwood.

The structures are anchored to the trailer in a number of ways. I use decking screws going into the floor most of the time. Then for the wall I have created 2" strips of baltic birch that are attached to the walls and then the structure is tied into them. On the curved walls, I have done kerf cuts every 1.5" going just over 1/2" deep into the 3/4" baltic birch strips to allow it to bend. I experiment with the depth of cut to see how deep I have to go to get it to bend for whatever radius I'm working on at the moment. To attach these baltic birch strips to the walls and ceiling I invested in a very nice pack of metal screws that really grab into the Airstream. I use a screw about every 2" so there are lots of them and with that many I don't even think about weather I'm hitting a metal stud or not.

Hope that helps. Feel free to fire back any specific questions and I'll try to answer with better photos or explanation.
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Old 10-19-2009, 08:02 AM   #75
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Wow She is truly beautiful! You are a master craftsman!
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Old 10-22-2009, 11:07 AM   #76
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Air19, thanks for the additional explanation about anchoring your cabinets to the floor and walls. Forgive my ignorance, but are the 2" baltic birch strips (attached to the walls) of ply or solid wood? Any other information about the screws that grab so well?

Thanks again for your excellent thread.

Hank
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Old 10-23-2009, 08:08 PM   #77
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Hi Hank,

Please feel free to ask any questions you want. No problem. I might not get back in a day, but I get email reminders when someone has accessed this thread and that's when I usually check back in.

Regarding baltic birch, it is a special type of plywood made up of more plys than regular birch playwood. Baltic birch is not always available at a big box store, but check around. It comes in 5 foot by 5 foot sheets, but in Vermont I have found a source that actually has 8 foot by 4 foot sheets. For woodworking it is a great plywood because with those extra plys it is much more stable and stronger than normal ply. For my use of creating anchoring strips that go around the curves of the Airstream wall I wanted something that would retain it's strength even though I was cutting more than half way through it to be able to bend it.
I am using 3/4" thick baltic birch for the Airstream anchoring strips. Baltic birch also comes in other thicknesses with more plys than the comparable regular plywood. For example I used 5/8" thick baltic birch for the tops of my beds. That's possibly overkill and it did add extra weight. The other negative of baltic birch is that there is more glue used than regular ply and it has been noted to give off more glue fumes. Frankly I work with it alot and have never noticed this or had any problems. But for the tops of my beds I did have my wife (who applies the finish to all my wood working pieces) to finish not only the top but all the edges of these large pieces.

Regarding the screws. They are self tapping metal screws 1 and 1/4 inch long and 1/8 inch thick, but I don't rely on the self tapping. I predrill through the baltic birch and into the Airstream wall with a small bit (1/16) and then I predrill again into the birch with a slightly larger bit.

I have attached a picture of a strip of the baltic birch ply and the screws. Hope that helps Hank.
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Old 10-25-2009, 02:57 PM   #78
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Yes, your message was very helpful. I will head to the hardware store to get a supply of the screws. I will not be working with the plywood for a good while, but at least I can get the rest of the hardware I expect to need.

Hank
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Old 02-03-2010, 03:59 PM   #79
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The front lounge area is finally in progress

Hi Everyone,

Back again after a long absense. Getting ready for winter in Vermont and then working through it always seems to take me away from my fun hobbies, like working on the Airstream.

When I left you last it was time to start the design and buildout of the front end of our 53 Flying Cloud. Lots of progress has been made. My wife and I have spent countless nights talking through different designs. I've done half a dozen real sized mockups of various seating arrangements. And we have settled in on one design we think will work well.

We are trying to satisfy two major objectives with the front end - 1) to provide a seating area for eating, doing paperwork, and working on the computer, and 2) to provide a comfortable lounging area for watching TV or listening to music.

We originally were going to build a dinette up front on a slight angle to make access easy. We thought about sitting longways on the dinette benches to watch TV on the closet wall. When we mocked this all up everything was too tight.

We made a couple of breakthroughs with the design when we decided to switch the TV location to the front end on the street side by thinking about a cabinet area as an extension of the kitchen counter. Then we simplified the dinette into an "L" lounge.

The first goal of providing a seating area is easily solved by the L lounge and it doesn't feel as cramped as the full dinette. The second goal of providing a comfortable lounging area will be solved by providing two seating positions where we can put our legs up. One of these happens naturally on the L lounge when you put your feet up, the other will be done by a slide out foot rest.

Over the next month I hope to show you the entire buildout.
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Old 02-03-2010, 04:21 PM   #80
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Front lounge benches

The first of three steps in building out the front will be to get the lounge benches in place. Then we will build in the TV cabinet, and finally create and mount the table.

Starting with the benches I have just a couple of obstacles to work around up front - the fresh water tank set in the middle under the front window, and two batteries set on either side. There is also a small amount of wiring and the water pump by the battery on the street side of the fresh water tank.

I am building the bench area in four pieces - a curved area on the street side for battery #1, the front bench that sits over the fresh water tank, a curved area on the curb side for battery #2, and the side bench on the curb side.

Here's a couple of pictures of all four pieces in place that represents two full days of work in the woodshop. One of my overriding goals for everything we build out in the trailer is to keep it light weight. That starts with the framing which is all 1x2 softwood. For those of you who have been watching this thread you will notice some runners in some of the bench sections. And by now you should be able to guess what will go on those.
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Old 02-03-2010, 04:35 PM   #81
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More Bins of course for the front lounge area

Storage in the front lounge won't be ideal because with the table in place access will be more challenging reaching under the table.

But I did have some bins left over so I decided to try and fit them in. The bins actually are the main driver for all the dimensions because they have to fit tightly into spaces to slide along the runners. On the side bench the best access is just as you enter from the door so I turned the bin access in this area sideways - you pull the bins out into the door space and won't have to deal with the table. The other two bins will be partially under the table.

Then in the front lounge I was able to fit a low profile bin between the water tank and the bench surface. There will be one on the left and right. And the middle space will be where I build a slide out foot rest. Stay tuned for the picture it will be easier to understand. Just in front of the water tank I'm also going to build three "tip out" containers for paperwork, again wait for the picture.

Here's a couple of pictures of the bins that have been fitted.

I just counted my bins. I have 26 bins in total now spread throughout the Flying Cloud. I feel like a moving Elfa commercial. All very helpful toward my never ending pursuit for weight reduction. These bins with one plywood front make very lightweight drawers.
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Old 02-03-2010, 07:10 PM   #82
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Nice. I like L shaped sofas personally. They give the seating for one while another can lay out on the couch!
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Old 02-03-2010, 07:38 PM   #83
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Nice work, Mike. Your Elfa commercials have made a believer out of me. I'm definitely going to incorporate them into mine.

cheers,
steve
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Old 02-04-2010, 07:01 AM   #84
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Thanks for the update, and for your detailed explanations of your reasoning. I, and I believe others, find your thought processes to be valuable as we go through similar stages of our own renovations.

I am planning a front u-shaped dinette that will be similar in construction and utility to your L-shaped seating area. I had considered doing what you're doing, but since my Overlander is pretty roomy in the front lounge, I've decided to stick with the dinette.

Nice work and keep it up!

-Marcus
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