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C_Ferguson · 11-17-2007, 09:03 PM

Project: Transform a 1965 Safari into a tiny "Viewpod" trailer.

I found the raw material on Craig's list, Plattsburgh, NY. The trailer had already been gutted, saving me some work...

I spoke with Colin, the owner of the lot where the trailer was parked and told him of my plan. He invited me inside his shop to show me his own similar project, half finished. It was quite nice to be able to stand inside a space I had been imagining for the last few months. He generously shared his ideas and techniques with me.

C_Ferguson · 11-17-2007, 09:10 PM

Since the trailer was almost completely gutted, I started by removing the windows - hoping to sell them and make back some of the initial cost of the trailer. I am planning a rear door, with windows on each side. There are two identical windows that will work for this purpose - they are bit larger than I might have liked, but will make for a nice light filled space - and as good screens for rear-projecting video and images from the interior.

Removing the windows is just a process of carefully drilling out rivets with a 5/32" drill bit. Start the bit as close to the center of the rivet as possible, then continually lean the bit towards the center. The soft aluminum drills easily. Eventually the head falls off and the rivet punches through to the other side.

C_Ferguson · 11-17-2007, 09:19 PM

The interior skins came out the same way, drilling out rivets. Then the exterior skins. I lifted the endcaps off and set them aside.

C_Ferguson · 11-17-2007, 09:23 PM

Aluminum is 55 cents a pound, so I am carefully sorting all the leftover metal for recycling.

I had intended to use the old frame - cut off the last few feet and reposition the axle. The 65, however, has a much deeper and heavier frame than my 62, so I just cut it up with a torch for recycling. Instead, I'll fabricate a new frame from scratch.

C_Ferguson · 11-17-2007, 09:26 PM

I am using 3"x2" stock for the frame, it's probably much heavier than necessary, I'll make the next one lighter...

The coupler was still in good shape, so I cleaned it and the jack up to use on the new trailer.

I clamped things together with c-clamps, and went to Tigging.

C_Ferguson · 11-17-2007, 09:31 PM

I tacked things together first, to make sure the fit was good. The crosspieces are cut from 14 gauge stock, cut out with a plasma cutter.

C_Ferguson · 11-17-2007, 09:34 PM

The outriggers were cut on a bandsaw, then shaped on a sander.

C_Ferguson · 11-17-2007, 09:36 PM

The c channel will be re-used as well, and here it is used as a pattern for the curves. The floor material is 1/2" douglas fir ply.

C_Ferguson · 11-17-2007, 09:44 PM

The frame members are cut with a horizontal bandsaw, the edges cleaned with an angle grinder, pieces clamped together, then tacked.

soldiermedic · 11-17-2007, 09:56 PM

Carlos,

Another project for us all to look forward to. New screen name as well?

Steve

C_Ferguson · 11-18-2007, 06:54 PM

The outriggers are welded on in the same fashion as the crosspieces, clamped, tacked, and welded. The frame was laid out on a piece of plywood to estimate where some extra support outriggers would fit in the front of the trailer. One piece of 3x2" stock was cut in half on the bandsaw to fit in the sloped area at the front of the belly pan. I used a piece of angle iron to find the current balancing point to estimate where the axle should go.

C_Ferguson · 11-22-2007, 03:50 PM

The frame was sandblasted and washed, then painted with por15. I used lap joints on the floorboards made with a router. The elevator bolts that hold down the floor were countersunk with a forstner bit, then the original C channel was installed on the corners. Some new C channel spans the sides.

C_Ferguson · 11-22-2007, 03:53 PM

The two end cones were attached to the frame with clecos.

2333 · 11-22-2007, 06:14 PM

I thought this was a photoshop trick, until I read thru the post. I'm sure you'll get a lot of opinions on this making conversion, but either way....it's a lot of work and looks like you're doing it well, and seeing your other work, I am looking forward to the interior.

elbundi · 11-22-2007, 06:47 PM

i am very impressed at your skill and knowledge of working the metal, your trade i assume

very good mosaic you created in photoshop for getting the idea across. how's your cad skills?

robandzoe · 11-22-2007, 07:02 PM

Next year, in October, we are having our Washington DC WBCCI Unit Installation Rally down here in Norwich, NY. You need to attend with this very cool project. Will you be done by then? We might be having a Forums Rally here around the Sherburne Pageant of Bands June 5-8 here as well. What do you have envisioned for Interiors.

Rob

GreatPumpkin · 11-22-2007, 07:25 PM

Quote:

Originally Posted by C_Ferguson

The two end cones were attached to the frame with clecos.

Carlos -

Beautiful work as usual.

Is the wheel well going to end up in the door area, or will it be in the aft end piece? From your balancing act, it appears that you'll have to move a few outriggers, but I couldn't match that picture up with the "shell on" picture to see exactly where that was

On edit: I forgot you already mentioned that this is going to be a rear entry

Carry on with the cool project.

C_Ferguson · 11-22-2007, 07:36 PM

Quote:

Originally Posted by GreatPumpkin

Carlos -

Beautiful work as usual.

Is the wheel well going to end up in the door area, or will it be in the aft end piece? From your balancing act, it appears that you'll have to move a few outriggers, but I couldn't match that picture up with the "shell on" picture to see exactly where that was

On edit: I forgot you already mentioned that this is going to be a rear entry

Carry on with the cool project.

As far as the axle goes, I'm not sure yet where it should go (and am waiting 'til next week for it to arrive). I think I will get this top part more or less done, then find the balance point, then take the top off (it's pretty light), remove the center piece of plywood, flip over the frame and put the axle on the easy way, attach the last two outriggers, put on the belly pan, flip it again and put the top back on... I'll have a better idea where to put it on the next one I suppose without the extra hour or two of take off and put on. I'm guessing the axle will be centered more or less at the leading edge of the rear cone.

C_Ferguson · 11-22-2007, 07:37 PM

Quote:

Originally Posted by elbundi

how's your cad skills?

I keep meaning to learn cad but never get around to it...

C_Ferguson · 11-22-2007, 07:40 PM

Quote:

Originally Posted by robandzoe

Next year, in October, we are having our Washington DC WBCCI Unit Installation Rally down here in Norwich, NY. You need to attend with this very cool project. Will you be done by then? We might be having a Forums Rally here around the Sherburne Pageant of Bands June 5-8 here as well. What do you have envisioned for Interiors.

Rob

I'm still thinking on the interior... maybe some industrial linoleum on the floor, or tiles of plywood...

keep me updated on the rally.