'77 Excella 500 31' Off Road Build

[GPurcell]

Quite happy with what we accomplished this weekend. The front c-channel is fully riveted and we have the new panel hung. Also placed the leveling jacks in their proper locations.





Very happy with panel fitment and I think we did a great job for two people who have never done this before.





You'll notice how large those rivets are. We are using #40 aluminum rivets in all of the holes created by the larger pop rivets that were used before.



Never enough clecos...



Final fitment. Everything is nice and tight. It's not perfect and learned some good lessons on what to do with the next panels. It's not too bad once we figured it out but it is tedious more than anything else.

[kidjedi]

Looking good! I actually love those huge rivets!

"Never enough clecos..."

I TOLD YOU!!!!

[PeterH-350LE]

Originally Posted by GPurcell

..


Final fitment. Everything is nice and tight. It's not perfect and learned some good lessons on what to do with the next panels. It's not too bad once we figured it out but it is tedious more than anything else.

Looks great, what type of sealant did you use on the panel seams?

[GPurcell]

Originally Posted by kidjedi

Looking good! I actually love those huge rivets!

"Never enough clecos..."

I TOLD YOU!!!!

You were right already ordering more

[GPurcell]

Originally Posted by PeterH-350LE

Looks great, what type of sealant did you use on the panel seams?

Trempro

[GPurcell]

Well opened up the boxes with the rest of my panels just to see how they look. I'm glad I did... Airstream sent me a wrong panel.

Ordered through high sky and they got it right. Airstream themselves packed and shipped the wrong one. Should be fun seeing how long it takes to get this last panel with everything going on right now.

The wrong panel that was shipped...




I need 104452-015 not 104452-02. I need to replace the center section in the rear

[GPurcell]

Very nice progress this weekend. Girlfriend's father was up at the farm with us and the extra pair of hands was quite helpful.

Both new wing windows installed.









Butyl tape and Trempro have them sealed nicely. You'll notice our screw up on the curb side panel. Don't cut too much too soon... won't do that ever again.

In the rear, started removing all the various pop rivets. Removed and replaced all of the pop rivets on the panel that is staying. Doing it right.







Leaving a few holes with no rivets so we have some wiggle room with the new panels. Also need to massage this bent rib. Someone definitely backed into a tree with this trailer.

[kidjedi]

Looking good!

I can't tell if that bent rib actually has a break/fracture at the bend, but it might be worth riveting a piece of C channel over the part that was bent/broken once you've got it straightened out a bit (rivet on the side, not the face so the rivets don't interfere with the skin). I always overbuild, so take this advice with however many grains of salt you feel are appropriate.

EDIT: Unless you've got extra rib material; then use that. I just suggested C Channel because it's easier to source.

[GPurcell]

Originally Posted by kidjedi

Looking good!

I can't tell if that bent rib actually has a break/fracture at the bend, but it might be worth riveting a piece of C channel over the part that was bent/broken once you've got it straightened out a bit (rivet on the side, not the face so the rivets don't interfere with the skin). I always overbuild, so take this advice with however many grains of salt you feel are appropriate.

EDIT: Unless you've got extra rib material; then use that. I just suggested C Channel because it's easier to source.

Thank you!

Luckily no breaks in the rib. Just bent. The idea with the c-channel is a good one! I need some for a small potion of the floor where the water heater used to be so I bet I will have extra from that.

[kidjedi]

I just want you to get that Guinea Pig on the road so you can tell me if I should go ahead and build my next chassis with those Timbrens!

[PeterH-350LE]

I suppose now we know what happens when you hit something hard with your upper awning support Amazing how strong the airstream structure is

[GPurcell]

Originally Posted by kidjedi

I just want you to get that Guinea Pig on the road so you can tell me if I should go ahead and build my next chassis with those Timbrens!

Ha! You and me both. With what I have experienced so far, this thing should ride like a dream.

[GPurcell]

Originally Posted by PeterH-350LE

I suppose now we know what happens when you hit something hard with your upper awning support Amazing how strong the airstream structure is

Upper and lower awning supports were totally ripped off the trailer on this side! Whatever they hit... they hit with authority.

[kidjedi]

Originally Posted by GPurcell

Whatever they hit... they hit with authority.

[Ginophiles]

Just wanted to say this thread has been amazing, really enjoy it.

Before settling on our AS, we where seriously considering driving to Utah to check BlackSeries off road travel trailers. As badass as they were, we realized for us it would be like buying a Jeep Rubicon to go to the mall with.

But now, I may have to look for an old AS to turn into an off road beast like you did.

Look forward to seeing this thing on the road someday in person.

[GPurcell]

Originally Posted by Ginophiles

Just wanted to say this thread has been amazing, really enjoy it.

Before settling on our AS, we where seriously considering driving to Utah to check BlackSeries off road travel trailers. As badass as they were, we realized for us it would be like buying a Jeep Rubicon to go to the mall with.

But now, I may have to look for an old AS to turn into an off road beast like you did.

Look forward to seeing this thing on the road someday in person.

Thanks! I'm ready for it to be on the road. Hopefully that may happen in June as an empty shell. Start using it for some camping trips to get an idea of what to build it out as.

[PeterH-350LE]

Originally Posted by GPurcell

Thanks! I'm ready for it to be on the road. Hopefully that may happen in June as an empty shell. Start using it for some camping trips to get an idea of what to build it out as.

I would start with insulation and AC

[GPurcell]

Alright another panel will be done this weekend. Decided to tackle the passenger top curved panel first for the rear.



All of the rivets removed that hold the panel in.









This one was absolutely trashed.



We realized that for the best possible fitment... we should remove the window frame... so that came out too. This is escalating quickly.



With that out of the way, we started getting the new one fitted. Unlike the panel in the front, this one has NO excess material other than where the window goes. We had to get the fitment perfect.







Once again, buying panels from Airstream proved to be the right choice. The curves are spot on and honestly I have no idea how we would bend the panels ourselves.





Will still have to make a patch for where the awning support was. Other than that, all holes got covered.



Small dent in the middle panel that will be saved. They really hit it hard back here and tweaked everything.



And that's where we are at for today. Tomorrow we will have it riveted in for good. Hopefully the window frame back in too after I clean all of the copious amounts of adhesive off.

[PeterH-350LE]

very smart move to replace 1 panel at a time to keep the curvature !
Another interesting fact most folks don't know: if you plan on stripping the panel and polish it later, you should really strip it at least on all the seams prior to installation. Why? Because Tempro 635 and Vulkem 116 only sticks marginal to clear coat, however they almost make a permanent super strong bond alu to alu. Just also have to make sure to remove oily residue on back of next new panel and/or crap on old

[GPurcell]

My trailer has a mohawk.



Fitment was perfect. We got it better than the stock panel was honestly.



My hand is hurting pretty good from all the buck riveting we've been doing lately. And there's still so much more lol.