79 Excella 500 31ft - Full rebuild

[richard5933]

Great solution on the bolts. Almost too bad you've got to cover them up - sort of looks like a bit of industrial art.

[Sylvain]

Originally Posted by richard5933

Great solution on the bolts. Almost too bad you've got to cover them up - sort of looks like a bit of industrial art.

I always have the solution of not installing the interior skin back on ahahahah
There were several solution for that problem, it is the best one I came up with that was not a pain in the butt and I did not have to go contently back inside between each bolts

[Sylvain]

now I have only a few floor bolts to add, fill the bolts holes with body filler and that will be done. I am looking to do that the coming weekend. After that I will be able to camp in it! However, I can't do that were it is located so I plan to move it to the nearby RV park. So before that I have to be done with the exterior as they won't let me do that at the park. I still need to figure out if I'll be able to recover the shell from the scuffed marks to a polished finish or if I go for brushed metal finish

[Sylvain]

PROGRESS REPORT:
finally done with the subfloor! filled up the recesses for the floor bolts with body filler, sanded and painted it. A big step is over. It took only 64 hours and about $4300 ahahahah. Just below 300 hours total.


Now time to get back on working on everything outside which I can't do at the campground.

https://www.youtube.com/watch?v=mGqvDCgBUCs

[dbj216]

That is a big milestone in your project. The subfloor is a very important structural member of the Airstream overall construction. As they say, the frame holds the body up, and the body holds the frame up. The subfloor stiffens and strengthens the whole mess.

Now on to better things in your project, like electrical, plumbing, finishing, cabinets, appliances, etc, etc.

David

[Sylvain]

Originally Posted by dbj216

That is a big milestone in your project. The subfloor is a very important structural member of the Airstream overall construction. As they say, the frame holds the body up, and the body holds the frame up. The subfloor stiffens and strengthens the whole mess.

Now on to better things in your project, like electrical, plumbing, finishing, cabinets, appliances, etc, etc.

David

A bit early for that, although I am thinking actively about it. Right now I have to do everything that is outside, like polishing etc... the RV park will not let me do that there

[dbj216]

Polishing! Ugh. I've spent all winter and spring polishing Airstreams. First photo is the DW's 86 Limited 34'. It was corroded from road deicers. Second, I polished my 75 Overlander 27'. It too was corroded just from years of weather in the southeast. Now I'm polishing my son's 69 Globetrotter 21'. It is made with Alclad aluminum which makes polishing a bit easier.

Ugh. I don't envy you. I spent maybe over 100 hours pushing a polisher around on my Overlander, and the same on the Limited. It's boring drudgery work for me. But maybe, just maybe it is worth it.

David

[Sylvain]

they look really nice!
I am almost done getting rid of every bit of the paint. After that I don't yet know exactly how to start since it is entirely scuffed.
Should I sand that with finer grit before doing the polishing process?


I might go with brushed metal look, maybe...

[Sylvain]

Right now it looks like that

[dbj216]

I have Airstream Forums post that suggest your 79 was made with H 3004 - H18 Alcoa "Brite" sheet aluminum. The post was by user ZoomZoom from California and dated 2/7/2010. Post title was Interior and Exterior Skin Material Confirmation.

My 75 Overlander was built with 6061 T6 aluminum sheet. I found it a bear to polish as the surface hardness was, well hard. The 3004 H18 spec shows a softer surface hardness, so maybe yours will be easier to polish.

I "sanded" my Overlander with green Scotch Brite to help scrape off the corrosion. Then I used my angle polisher and a sewn cotton buffing wheel at 2200 rpm and Caswell "black" polish bar. This seemed to work on the Overlander, see photo. You might want to try a less aggressive grit first on your trailer to make sure you don't leave "grind marks" in the aluminum.

Certainly your Sovereign will look much better polished. Polished Airstreams are an attractive nuisance.

David

[Sylvain]

Thanks for the tip!
I actually tried steel wool tonight on the door, it does a wonder at removing the paint residues and the scuffed marks! however, I was just told that I should not be using that as metal particle would stay in the aluminum and create more corrosion. I'll try with scotchbrite as you suggested

[Bubba L]

Originally Posted by Sylvain

Thanks for the tip!
I actually tried steel wool tonight on the door, it does a wonder at removing the paint residues and the scuffed marks! however, I was just told that I should not be using that as metal particle would stay in the aluminum and create more corrosion. I'll try with scotchbrite as you suggested

I’ve used aluminum wool before for hard to get off stuff. I don’t remember what grades it comes in, but try it. Good luck

[Sylvain]

Originally Posted by Bubba L

I’ve used aluminum wool before for hard to get off stuff. I don’t remember what grades it comes in, but try it. Good luck

Do you find that at standard hardware store? I did not know aluminum wool existed.

[Bubba L]

I don’t remember where I used to get aluminum wool, but I checked Walmart’s site here in Fredericksburg and they have it.

[Sylvain]

Was not able to find aluminum wool available for pick up locally. But I gave a shot at 400 grit with the orbital sander. It gets rid of all the residues, now I am able to see where I will need to re-apply a bit of paint stripper.

[Sylvain]

PROGRESS REPORT: The 400 grit with the orbital sander works really well. See the pictures. It takes time but it is getting there. I have two curved sections on the front that are now shining with the sun! Not polished yet but with all the paint gone I am starting to see an Airstream somewhere.
Something that is interesting to me is the corrosion left on the aluminum by the double sided tape that was used on the back of the blue trim band. Could that have trapped water over time and corroded it?

[Sylvain]

It is getting somewhere. The difference is obvious

[dbj216]

That sure is a lot of work to sand off that old paint someone foolish put on it. It does look better, and even better yet if it were polished. You can do that someday when you feel like it. But it will make your trailer look like new.

David

[Sylvain]

Polishing is the current plan, if I don't change my mind. For now, still have some more sanding to do to remove that stupid paint