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Old 09-07-2016, 11:04 PM   #155
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2012 30' Flying Cloud
1955 22' Flying Cloud
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More window sill repair

Through the process:
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Old 09-07-2016, 11:08 PM   #156
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2012 30' Flying Cloud
1955 22' Flying Cloud
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One more sill cleanup

One more, just because I am so happy to see the change in the condition.
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Old 09-08-2016, 05:27 PM   #157
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For me, it's been easier to build new frames than mess with the old junk. I went with overlap joints.
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Old 09-08-2016, 07:05 PM   #158
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2012 30' Flying Cloud
1955 22' Flying Cloud
Lansing , Kansas
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Thanks, fortunately I didn't need to fabricate the sills. I did need to do several for the the retention brackets, and the cargo door in the rear.

I like your design. Nice and clean look.
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Old 09-08-2016, 07:07 PM   #159
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2012 30' Flying Cloud
1955 22' Flying Cloud
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New project this week

I have a new project starting this week. I am trying to figure out how to document it, but it should move quickly. Here's a little hint:
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Old 09-26-2016, 08:49 PM   #160
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1955 22' Flying Cloud
Lansing , Kansas
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Window opening clean up

Cleaned up some of mess around the windows. There was still butyl tape from 1955 in place. I also had to apply various kinds of tape to cover the windows during storage while moving. The tape did not want to come off easily. The ordinary adhesive remover was not able to do much of anything. Acetone was a bit better. Citristrip seemed to do the best job by far.
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Old 09-27-2016, 09:40 PM   #161
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2012 30' Flying Cloud
1955 22' Flying Cloud
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New glass

The first window was slow, but easier than expected. I ordered glass from a local window place. For the smaller windows on the sides, I went with ordinary glass. Using the window seals from VTS for the outer frame, these were attached first after measuring and cleaning. Truly, they dirty easily, so clean hands are a necessity, and I used mineral spirits to clean what aluminum oxide, etc. was on them.

Seeing how others had used a bead of silicon sealant, I tried it on the first window, but am not seeing the benefit. The rest did not get one, as it just made a mess.

For several windows, I fabricated new retention brackets out of sheets of 3003 aluminum. I did not like the original style retention screws, so I used short length 3/16” pop rivets. They fit almost perfectly in the original holes. Pop rivets also had the virtue of drawing the two fastened surfaces together.

I quickly learned that for the larger windows on front and back and the two large ones on the front that tempered glass was preferable, breaking a couple on the way home.

The opener adapter brackets supplied by VTS worked well, although for the two very small windows, I needed to drill and additional hole to make them work. I also had to cut the adapter arm on the shorter windows and then redrill the slide tab hole again.

Trimming the screen was a little fiddly at first, but eventually a good set of shears made the cleanest cut to size. I still may put in the cord around the edge to give it a cleaner look and keep it more secure if I can find the right thickness.
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Old 09-27-2016, 09:58 PM   #162
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A few more

A few more pictures. I also used 1/8” pop rivets to hold the center bars in place. This required a bit of drilling to make the small adjustment to size. When doing the large pieces, I needed to prefit everything to ensure that it would all fit once I started riveting.
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Old 09-28-2016, 07:01 AM   #163
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Fantastic tutorial Matt , thank you, looks great
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Old 10-01-2016, 09:53 PM   #164
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1955 22' Flying Cloud
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Fixed the rear cargo hatch

The rear cargo door was in poor shape and could not open or close. The interior panel of the door just seemed to be past saving. Using a new piece of 2024, I used a metal brake to bend the sides to reshape it to go over the old outside panel piece. I also removed the brand placard and gave it an initial cut of polishing. The frame is relatively white after experimenting with an acid etch for the windows. I couldn’t make it work as well for the rest of the window frames.

I installed a new baggage lock from VTS. Though I changed the design a bit to keep the interior mechanism entirely inside the door, instead of running through both inner and out door. Though I still have a little bit of trimming on the frame slot to get it completely smooth in locking, it works fine.

I clamped it into place after insulating it with foil insulation. Then drilling holes in the outer panel to align with the old ones, and I riveted it together. Still haven’t completed the rear Airstream brand logo placard. Some painting is in order for that.
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Old 10-03-2016, 08:21 PM   #165
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Rear placard restoration

I thought about leaving it as it was, without any paint, but I don’t like the look. I polished the letters, and then put masking tape over the newly polished letters, and then cut carefully around their outline with a hobby knife. Not perfect, but nothing that could not be touched up.

Then primed with metal etching primer. Then blue paint, matched as closely as possible the Airstream shade, which I think is slightly lighter than the shade on the reproduction placards from VTS. Nevertheless, I will add an additional placard on the front that wasn’t there originally, just because I want to. If Wally Byam could add them all over his trailer, I can add one extra to mine.

Then peel the tape and touch up with primer and blue paint. Once that was dry I clear coated over the whole thing.
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Old 10-03-2016, 08:35 PM   #166
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2012 30' Flying Cloud
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Last window

Finally, and cue the angels singing soundtrack, the last window is together.

I tried regular glass in the larger windows on the sides, but had issues with breakage just getting them home and then as I installed. I went with thicker tempered glass and it worked like champ. I had just enough of the shallow depth 3/16" rivets to make it work.

After something like 200-250 hours on these things, I think I shed a few tears as I wrapped it up. That may also have been a result of smashing my index finger with the rivet gun. Let's just say it was bad enough that I felt a little nauseous and weak in the knees.
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Old 10-03-2016, 09:23 PM   #167
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Nice work Matt but what's the new project trailer
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Old 10-04-2016, 10:25 PM   #168
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2012 30' Flying Cloud
1955 22' Flying Cloud
Lansing , Kansas
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More to follow on the new project trailer. Just need to get my digits to talk to one another and get the pictures downloaded from one device to another that are not normally connected.

Thanks for asking. I think once that project gets really rolling, it will go stunningly faster than this one.
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1955, air conditioning, axle, door, flying cloud, frame, holding tanks, polish, restoration, shell off, tank heater, window


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