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Old 05-07-2018, 11:55 AM   #1
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High Point , North Carolina
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Replace Plastic End Caps with Aluminum?

Hello,
I'm working on a 1977 Sovereign, and while the plastic interior end caps are in decent shape, they do have some spider cracks and I'm imagining they'll suffer even more if we try to reattach.

I've seen pictures online of end caps that have been replaced with cut aluminum sheeting. Is there a pattern available for this or a kit sold online anywhere?

Thanks for any advice,
Dave
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Old 05-07-2018, 12:45 PM   #2
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11 peices 48 x 11 comes out like this.
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Old 05-07-2018, 12:53 PM   #3
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Bought a full sheet from aircraft spruce shipped in a roll and had friend at metal shop sheer me the peices. Drilled one side while stacked together the assembled in place one at a time pulled down to buck rivet each. This was a pain to do and pop riveting would be way less work if that suits you
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Old 05-07-2018, 03:16 PM   #4
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Replace Plastic End Caps with Aluminum?

It also can be done in 1/16 plywood. I did 9 side panels at 48x12 with a 48x24 center panel on the front. I used buck rivets. The rear panels are longer but the method was the same. Aluminum would be easier. [eClick image for larger version

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Old 05-08-2018, 09:09 AM   #5
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Quote:
Originally Posted by superdave74 View Post
Is there a pattern available for this or a kit sold online anywhere?
If I understand your question correctly, you're looking for the end caps that open and shut Airstream windows.

My plastic ones fell apart when the camper was only 3 years old. I bought metal ones online and they work perfectly:

https://www.vintagetrailersupply.com...-p/vts-294.htm

Happy camping!

Glenn
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Old 05-08-2018, 10:04 AM   #6
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Ya its a shame that Airstream doesn't support it trailers... and have replacement stock on the end caps. We went through the same thing with the 85 having the front one start cracking due to heat and stress, etc... We joined the many who also had the same problem.. and went the way like others here with fabrication of options.

We looked into having them made from fiberglass .. and actually the shop that we worked with came up with a great replacement price based on one's and two's of production...

Its strange that Airstream with all its engineering didn't plan on having end caps that would stand the test of time.... or produce one out of Alu... that was drawn similar to the other parts they machine. Leaving the owner/user to fend for themself is not very nice.

I noticed that in one of the pix the owner has replaced the insulation with foam.. interesting to find out what R value and sound absorb it provided. I know that some of the other manufactures who used foam had some issues with trapped moisture and corrosion under it.

Its a shame that avion or one of the other trailer manufactures don't start back up producing... now that the RV industry is booming... so we can have a choice..
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