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-   -   Now It Starts... Rebuild of Audrey (http://www.airforums.com/forums/f115/now-it-starts-rebuild-of-audrey-160491.html)

Mansderm161 01-14-2019 04:46 PM

Obviously, but when you are done, we are all going to oooh and aaaah!

Bubba L 01-14-2019 05:39 PM

Wise decision. Better to do it and move on. There are many who didnít and wished they had.

islandtrader 01-21-2019 04:05 PM

More removal...
 
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Quote:

Originally Posted by Bubba L (Post 2199852)
Wise decision. Better to do it and move on. There are many who didnít and wished they had.

Following Bubba's mantra, and because I had a little Alclad left over I decided to replace one more really ugly panel. This one was a breeze. The only hangup is that nothing is square on the airstream to a little bit of trimming with one of my favorite tools, and now we are good to go. When it the weather get back to normal around here...FLA in the low 50's sucks, I will get the tempro out and start bucking the rivets in...
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islandtrader 02-03-2019 09:12 AM

Big Hole
 
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Got a little more work done in the last few days...Weather has finally warmed up and even more importantly the wind has settled down .

Needed to cut in my tail lights...so for that you need a B I G hole saw . Then did a little riveting on the the door side.

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Hopefully will get one of the rear panels in today b4 the "Big Game"

islandtrader 02-09-2019 05:11 PM

Good News and Bad
 
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The good news is I installed 2 windows today...the bad news is I had to install the same window twice...:angry:

I have read a few threads on how to install the D gasket behind the window frame. So in my mind I knew what and how I was going to proceed.

The problem began when I tried to reuse the same holes that where there. In most cases that is an easy thing to do. However with these 13 panels the problem is that at the factory they used the rivet tool to pound down the frame around the panels. This led to elongated holes and blah blah blah.

Final out come was drill new holes, but first pound down the frame around the 13 panels remove and do it all over again. Thank goodness this is only on the front window. Learning curve...

The other windows should be easier...

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islandtrader 02-18-2019 04:55 PM

More windows
 
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Let me tell you for those out there that don't know. Tearing out windows and then putting them in is a real P I A . Each set has there own set of rules, and different challenges. If I had to give any advice I would say look for a better alternative than taking the gasket out. Of course the Caravanner has 9 windows...but whose counting.

Sunday I got the curbside next to the door double windows in. Just a lot of rivets and need to modify my bucking bar. The other challenge is I bought some eye brows that have the right shape, however they have some pre drilled holes...that of course do not line up with my holes...so must rivet the old ones shut and then make more holes in the tin can.

Monday was setting up a new window that I had made. (the original window was gone and the PO had some ugly slide window put in that never looked good or worked).The Hvac did a nice job in fabbing the frame and the casement. However there still needed to be a few tweeks here and there. Plus I needed to make a center support and re do one glass pane holder that was not bent correctly.

On the back center support...I had a old small window that I got someplace and I took out the support. Cut it in half and then sistered it into some aluminum channel. Looks good and it works.

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Camper Crazy 02-20-2019 11:12 AM

Good work Islandtrader! That area has come a long way. I really appreciate your detailed pictures and explanation of your process. Always look forward to your next post.

HiHoAgRV 02-21-2019 05:37 PM

Cool work. A few years ago I had the pleasure of working with VTS to help get those extrusions recreated. I really needed a few and Steve took my drawing and had the die built, saved my bacon because I had run out of options to replace a missing window. I can't help but smile to see them being used!

islandtrader 02-22-2019 07:14 AM

Nice Story
 
Very nice story...glad you shared it.

After doing some trial fits with new window openers I found out I need two more of these to make the windows open smooth. Your idea keeps on giving.:D

islandtrader 02-27-2019 09:24 AM

Window Operators
 
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All of my "window cranks are shot" considering the Caravanner has 9 windows, this adds up $ quickly.

You can buy openers from VTS (I did) my small windows (3) had what I call the standard crank(hehr) that fits into the channel with a S/S adaptor. The larger windows had a opener that is the same size as a clear view opener. The only difference is the clear view had a pressed in button. I like the larger opener for the big windows ...so some adaptation had to be made.

Basically all you have to do is punch out the button; then drill the hole out to 1/4 and round off the end and insert the plastic slide and it works and fits like what was the original with no adapter.

Hopefully these pictures will tell the story.

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islandtrader 03-15-2019 04:47 PM

Another Milestone!
 
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I always try to think of what is major amount of work...

Lifting the shell off...belly pans...putting the shell back on...

Taking windows out...Putting windows back in.

All windows are in :lol: and now on to the doors...

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islandtrader 03-20-2019 04:50 PM

Fun Project
 
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Today I decided to do an easy no brainer project...easy yes, no brainer no, but fun anyway.

I never liked the way airstream chopped up the belt line trim on the earlier models like mine. I plan on running the belt line all the way around. The only hard part is putting the seams where they are the least conspicuous. I will use 3 16' extruded strips. The seams will be in the front and back.

The front is laid out and clecoed...on to the rear on friday.

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Bubba L 03-20-2019 06:04 PM

Quote:

Originally Posted by islandtrader (Post 2222313)
Today I decided to do an easy no brainer project...easy yes, no brainer no, but fun anyway.

I never liked the way airstream chopped up the belt line trim on the earlier models like mine. I plan on running the belt line all the way around. The only hard part is putting the seams where they are the least conspicuous. I will use 3 16' extruded strips. The seams will be in the front and back.

The front is laid out and clecoed...on to the rear on friday.

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Iím guessing youíre planning on pop rivets for attachment? The problem I have is my trim is 1/2Ē from the skin to the face of the trim. So, Iím guessing pop rivets may not come long enough to go through everything and end in the C-channel. Originally AS attached those with steel sheet metal screws. Iíll go back with screws. Maybe stainless sheet metal or 8-32 rivnuts. What do you think? If I didnít already have the original trim and spent time on polishing, I would go your route. Youíre making headway.

islandtrader 03-21-2019 07:08 AM

Quote:

Originally Posted by Bubba L (Post 2222331)
Iím guessing youíre planning on pop rivets for attachment? The problem I have is my trim is 1/2Ē from the skin to the face of the trim. So, Iím guessing pop rivets may not come long enough to go through everything and end in the C-channel. Originally AS attached those with steel sheet metal screws. Iíll go back with screws. Maybe stainless sheet metal or 8-32 rivnuts. What do you think? If I didnít already have the original trim and spent time on polishing, I would go your route. Youíre making headway.

Actually I plan to buck rivet them on. So far every hole drilled -1 has been in the c channel and the cleco's go all the way through the trim, outer skin and the belly pan skin. So I think I'm good to go.

This trim piece if I remember correctly is off a 70ish Airstream and is stocked by AS. Being extruded and not stamped like the original piece makes it much thinner. It also has grooves in the edges so if you want you can add vinyl trim.

islandtrader 03-22-2019 05:05 PM

Belt Line
 
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Finished up the belt line. Beauty is in the eye of the beholder and since this is a renovation and not a restoration ...I like it. :D

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Airspry 03-24-2019 03:30 PM

I was hoping not to take out the window frames. Now I am rethinking that decision. It's a lot of work, but... I do not want to regret not having taken that extra step when everything is back together.

islandtrader 03-28-2019 07:59 AM

Quote:

Originally Posted by Airspry (Post 2223584)
I was hoping not to take out the window frames. Now I am rethinking that decision. It's a lot of work, but... I do not want to regret not having taken that extra step when everything is back together.

The main problem is you have to be real careful in drilling out the out rivets. If you double drill the hole, then you need backing washers...don't ask me why I know. :lol:

islandtrader 03-28-2019 09:09 AM

Luggage Door
 
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My luggage door area was all banged up do to a blow out, so the bottom half channel and the lock area had to be re-built. The pan and cover were so beat up, that I had them fabricated . As the story goes when you start down the slippery slope be careful...LOL. Getting the lock in and making sure the new slot was in the right spot was a challenge, but we got it done.

Just a word of advice...someone once posted DONOT use the old holes on a new piece of aluminum as your pattern.

The pan and the front cover were the exact same size but when I marked the holes using the old cover they did not line up on the new pan. I just used the holes for spacing and then adjusted from there.

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islandtrader 04-09-2019 04:49 PM

Some small steps forward
 
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Today water tested the windows...8 out of 9 passed. Number 9 got a A- :D Easy fix on the way.

Also took care of a problem with the running lights. Over the years the holes have been elongated and a "bigger screw " was not an option. Also I did not want to use nut inserts for too many of my own personal experience working with them.

Solution was to put a patch on them. To keep it clean the patch was on the inside, allowing for new holes to be drilled.

Finally even though it is far from done I put the door on for a trial fit. Installed a temporary door knob that was on there from the PO. I will say one thing, people sure do torture these airstreams. The whole locking area is one mess. I do have the original H20 so I will get that to work as a in and out handle and install a dead bolt where the door knob is now.

Next to do is finish sealing all inside seams and water test.

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HiHoAgRV 04-09-2019 09:42 PM

Nice solution to the oversized lamp holes. I also have had issues with nutserts. When they work, they are nice. When they go bad it's a real mess. On the door, the '55 I did was made from 100% formed flat stock, making repairs much easier than cast framed or bent extrusion doors.
Really top shelf work!


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