Renovation almost complete

[David F]

Just a few more finishing touches and system test and my '67 will be ready for the maiden Voyage. Major upgrades/changes include:

Polar Cub AC
new converter (Boondocker 45amp 4-stage)
Battery Monitor and disco switch
Granite counter top in bath and next to entry door
SS Galley countertop
Delete Gallery overhead cabinet
Paint all walls and woodwork
Waterless toilet (deleted gray tank).
Cooper walls in bath
Single Stage automotive paint on bath fiberglass
New custom design gauchos on Hafele slides (will be power actuated in future)
Micro blinds (not yet installed)
Linen cushions
LED lighting throughout
Custom exhaust fan
Wood refrigerator chimney

[David F]

Another photo (edit time limit got me).


Sorry for blurry photo...TV will go on the countertop. Wood brace is holding granite in place while adhesive sets.


12v distribution, battery monitor and disco switch, LP/CO sensor. PEX water pipe now has wood cover installed (also houses coax TV cable).

[DeepRock]

Great job, looks awesome!

[Monza]

Really nice, good job.

[tabney0315]

Looks great. Please share more pics!

[tabney0315]

Can you share more details about the exhaust fan?

[dmbecke]

Very nice
Congrats on getting close

[David F]

Just need to add micro blind window treatment and a cabinet door or two. Plastic still on cushion to protect them from me while finishing up. The plastic will be removed after I receive and install window treatment...

Cannot use Photobucket any longer, so trying Igmur...cannot get image embedment to work, so here is link.
http://imgur.com/a/eQhS9

[David F]

Originally Posted by tabney0315

Can you share more details about the exhaust fan?

Here is the sketch I drew for the exhaust fan. Used original fan motor, purchased grille online somewhere and had the sleeve made. Damper was cut from mill grade heave gauge stainless.

[David F]

I figured out how to post from Igmur hosting...

[lakemaiden]

David F - I recently became the owner of a 1966 Caravel, and so I am a latecomer to this thread...the work you have done on your Caravel is masterful and very thoughtfully done. I am particularly interested in the wood cover you fashioned for the refrigerator chimney. Any chance you did a drawing for that too? Mine is in fair to rough shape -but I don't want to replace it since the new ones that are available are 4 inches too short...

I have decided to try to preserve the original wood, and so I have hand-sanded all of the cabinetry and have waxed them. I plan to go back over them when it cools down and add a Monocoat finish. Having seen how calming your painted cabinets look, I am thinking I must be a bit nutty...though I am beginning to think you need to be.

The TV -- what system did you use to bring the trailer into the 21st Century? [I actually still have the original antennae!]

I am wondering if you did this work yourself, or whether you took it to an Airstream specialist? I look forward to hearing from you. LakeMaiden

[55AS]

I installed the same cooktop in my 55 Safari. Looks and works great. Any idea how much weight you have added?

[Argonaut20]

Lake Maiden: You can do some rebuilding of the refrigerator scoop using fiberglass. It takes time and patience but the result will fit and paint can hide some problems. If the scoop is too far gone, you can make one from wood and aluminum sheet. It is a "cut and fit" task to get the sides right so they seal to the wall, but it can be done. Whatever you do, the scoop has to act as a chimney that keeps carbon monoxide from the living space.

Kudos on the work to keep the wood in your Caravel. It keeps that period look.

[David F]

Wow, it has been a while since I visited this thread. We love using our trailer and it is holding up well. To answer a few questions:

No idea how much weight I added. Since these trailers are so light to begin with, I was not concerned. A few hundred lbs added for sure.

The chimney: side panels are 3/4” plywood shaped to mimic original fiberglass chimney sides. Carefully scribed to ensure tight fit to wall. Sides held to wall via aluminum angle riveted to wall and screwed to plywood. Outer skin is 1/4” bendable plywood. Top is screwed to wood block screwed to trailer wall. Screws holding Cover to plywood sides were recessed and filled before painting.

Painting oak is a chore. It takes a lot of pore filling material prior painting.

The copper sheet in the bathroom is glued to the plywood...super simple and very waterproof.

The original sink is hiding under the granite and is unhurt. The vessel drain goes through the factory sink drain hole. The granite is held in place with silicon around the original facet holes and perimeter. Pill it up, and original sink if anyone wants to go back. I even painted it nice with the rest of the fiberglass with automotive single stage polyurethane paint.

TV: just a coax cable to exterior port on trailer for campgrounds that have cable connections. We have never used it. Instead, we use Apple TV via my phone hotspot. Super simple.

Next outing is with friends caravanning to west Texas in October.

[docflyboy]

David- did you ever get around to upgrading your slides to actuators. I've got a booth up front on mine, but a gaucho on the side with metal slides, not wood. They're a little loose and clunky and I'm about to start reproducing all my case goods in Honduras Mahogany. It nearly takes a cabinet pro to select the right slides. If you figured it out, would you please post. thanks, Jerry

[Bubba L]

Originally Posted by docflyboy

David- did you ever get around to upgrading your slides to actuators. I've got a booth up front on mine, but a gaucho on the side with metal slides, not wood. They're a little loose and clunky and I'm about to start reproducing all my case goods in Honduras Mahogany. It nearly takes a cabinet pro to select the right slides. If you figured it out, would you please post. thanks, Jerry

Jerry, for wooden slides that can handle any weight, why not go with smaller versions of Walter of Wabash slides? All you need is a dovetail bit.

[docflyboy]

Bubba- thanks for the suggestion. My metal slides are mounted sideways and don't take up much space from the drawers under the gaucho. I looked awhile back to see if Walter of Wabash slides were still sold, and I did not see them. Do you have any specs or a reference to how much clearance is the right amount if you make them at one's router station? Jerry

[Bubba L]

Originally Posted by docflyboy

Bubba- thanks for the suggestion. My metal slides are mounted sideways and don't take up much space from the drawers under the gaucho. I looked awhile back to see if Walter of Wabash slides were still sold, and I did not see them. Do you have any specs or a reference to how much clearance is the right amount if you make them at one's router station? Jerry

Jerry, I didn’t want to get off subject on David F’s thread so posted on yours concerning fabricating Walter of Wabash slides as shown on post #220 on our thread. Hope it helps

[David F]

The slides I used are Hafele flat slides. Don’t remember the details, but they are rated for well in excess of the weight I could possibly put on them when extended. I used four per couch/bed. Each probably rated for 200 lbs or so. The have friction keepers in the collapsed and extend positions so they stay put. Sorry, not at my office so cannot look up part number.

I have not installed actuators because it is just so easy to pull out and push back in manually.

[docflyboy]

David and Bubba-thanks. I ordered 2 pair of slides from Rockler that are copied off the Walters of Wabash design. I now understand the doubled cantilever element to the design, so it makes sense. I think I'm probably going to build by gaucho with these. I may use an actuator up front to hide a flat screen TV to keep the vintage look. Jerry