'77 Excella 500 31' Off Road Build

[GPurcell]

Window frame still needs cleaning before going back in. Obviously the panel is still rough cut for fitment around the frame.

That one buck rivet is an interesting one to me. Airstream had a pop rivet there and it holds the structural ribbing That is beside the window frame. That rivet holds it separately from the frame. Why do they do that? I don't know but we mimicked it anyways. Holds it nice and tight.

[GPurcell]

This randomly got delivered. This is what High Sky sent me instead of the center panel in the rear. Apparently Airstream doesn't make them anymore.



I never got a tracking email for this. Nor have they sent me a label to return the panel that was wrongly sent. I still have not gotten the splines for the wing windows I ordered. The only reason why I have them done is because the new windows come with spline which I was not aware of.

I will not be ordering from High Sky anymore. On the flip side, if I never get a return label, anyone want that panel? I'll give a good deal

[PeterH-350LE]

Originally Posted by GPurcell

This randomly got delivered. This is what High Sky sent me instead of the center panel in the rear. Apparently Airstream doesn't make them anymore.



I never got a tracking email for this. Nor have they sent me a label to return the panel that was wrongly sent. I still have not gotten the splines for the wing windows I ordered. The only reason why I have them done is because the new windows come with spline which I was not aware of.

I will not be ordering from High Sky anymore. On the flip side, if I never get a return label, anyone want that panel? I'll give a good deal

Careful when you unleash that flat panel, its rolled up tight can really hurt you bad. Airstream typically does not send out out return labels for wrongly sent panels. Too much of a hassle, I suppose. Same with front window guards I once received damaged. I would love to get that panel from you, lets see if we can figure something out to get it to Austin cheap.

[GPurcell]

Originally Posted by PeterH-350LE

Careful when you unleash that flat panel, its rolled up tight can really hurt you bad. Airstream typically does not send out out return labels for wrongly sent panels. Too much of a hassle, I suppose. Same with front window guards I once received damaged. I would love to get that panel from you, lets see if we can figure something out to get it to Austin cheap.

Send me a PM

[kidjedi]

Originally Posted by PeterH-350LE

I would love to get that panel from you, lets see if we can figure something out to get it to Austin cheap.

Dang it! Missed it by that much.

[GPurcell]

Originally Posted by kidjedi

Dang it! Missed it by that much.

Not too late! If you want it, shoot me a PM

[GPurcell]

Unrolled the aluminum High Sky sent me. Peter - you were right. We put it in the grass and cut the tape. It came flying open



After replacing the panel, it un-tweaked a bunch of things and the window frame fitment was lacking. So we decided to redo the bottom section.





The seam and rivets will mimic the side panels. That center section actually has a bend in it made from a break. We don't have one of those so now the center panel will be two pieces. We will be replacing the entire lower section too.



You can see where the bend is along the rivet line. Instead of trying to recreate it, we will just have two panels now.



Finished product. Before putting it back in, I measured the window frame to make sure it's still square after seeing how tweaked and torqued everything was.

[PeterH-350LE]

Originally Posted by GPurcell

Unrolled the aluminum High Sky sent me. Peter - you were right. We put it in the grass and cut the tape. It came flying open

Yes, Garrett, it puts a rattlesnake to shame. They really should put a warning label on those flat panels. Imagine you open one of those in an enclosed area...

[Zcashio]

It’s all looking great! Nice work!

I always open my rolls of aluminum with a strap around them for safety. One time while filming, even with a strap around it, it sprung so hard that it knocked the camera off the table and broke the camera lens... definitely learned to have the camera far away on the next rolls!

[Bubba L]

Originally Posted by Zcashio

It’s all looking great! Nice work!

I always open my rolls of aluminum with a strap around them for safety. One time while filming, even with a strap around it, it sprung so hard that it knocked the camera off the table and broke the camera lens... definitely learned to have the camera far away on the next rolls!

That’s the way we do it. A strap or a rope with a loop. Just safer that way.

[GPurcell]

Only one pair of hands this weekend so no riveting. Did however get the panels removed that I wanted.





I keep running across this both front and rear. From factory, they installed the butyl but left the protective plastic on... so it wasn't doing anything...



What's funny though is it's still nice and tacky under the plastic. May just re-use it.



That's a big hole. Was fun getting that panel out.

[kidjedi]

Unbelievable on the not removing the plastic! Well... maybe believable.

[PeterH-350LE]

Originally Posted by GPurcell

I keep running across this both front and rear. From factory, they installed the butyl but left the protective plastic on... so it wasn't doing anything...

That has been my point for many years, when folks said you have to use buck rivets or it will leak. I have found that kind of seal on many seams and often was able to insert a blade or knife. The same holds true for Vulkem 112 or Tempro 635 on clear coat, it just doesn't bond as it would to aluminum. Yes, buck rivets are the way to go when you have full access to the inside, but failing to use proper sealing techniques defeats the purpose.

[GPurcell]

Almost have the rear of the Airstream done.

[GPurcell]

Other side.







Same thing with the butyl on this side. Plastic still on it.











Stopping point for today. Will finish the bottom row of rivets and middle section tomorrow.

[GPurcell]

Also going to fix this front section. We have a different idea than just patching the battery box locations.

[Mikebrady62]

Looking good!

[GPurcell]

Thanks! I'm excited to have this thing fully dried in.

I have to say this - I'm drinking my coffee, my hands are sore as hell, my shoulders, and my legs are not too happy with me after all that kneeling yesterday. I'm too young to be having these pains. With that being said, the skills and knowledge that I'm learning from having this trailer - this project - are totally worth it.

Ok. Back to work. I hope to be posting pictures of the rear totally done today.

[GPurcell]

Late on the post but here it is! Finished the curved panel





Fitting the panel.









This is as far as we got. Not quite done like I wanted but Easter stuff was more important.

[truckasaurus]

Lookin good