Hi Rhino,
I'll try to answer a few of your questions. I had an Airstream Excella 31 foot, and sold it to buy an Avion 34X. I have been very happy with the Avion.
- do the axles need replacing like AS or can a rehab of a say 60s or 70s model be sufficient with repacking the bearings?
In general, NO. Avion did not go to the rubber suspended axle like Airstream until mid year 1988. Any trailer older than that will either have the Adjust-a-Ride suspension (it's a Dexter axle cut in half, to make a swingarm that bolts to the center frame rail, so you get fully independant suspension) or the Mor-Ryde walking beam type suspension. Both are excellent. Both virtually never wear out. They went to Adjust-a-Ride in the mid 70's some time and had it until mid year '88. Before the mid 70's, they used the Mor-Ryde, which is probably even better.
- what are the issues with a floor repair. Is the floor like the AS set up, being a key component of the strength and structure of the unit?
Avion's floor sits inside the shell. You can replace the floor without unbolting the shell. Most Avions have a floor that is 1.5" thick, made in three layers. There are screws from the outside going through the shell into the floor, but the shell does not sit on the floor. It is easier to replace the Avion's floor than the Airstream's.
- what are the key flaws/expensive issues that I should be looking at for repair?
Go around the outside storage doors at the bottom of the coach and check the floor. Also inside the main entry door, check the floor. If the floor will have any problems, you will find it here.
Avion's frame is much heavier than Airstream's. You typically don't have much trouble with them.
Avion also tends to use more "standard" RV industry stuff than Airstream. So if anything, replacing stuff is usually cheaper on them.
- are parts like window/door gaskets difficult to find or is the same as for a vintage as
Easier.
- beyond curved windows, are there any parts that are particularly difficult to find?
I have a 1987 model, and I've found that standard "RV Normal Stuff" works on it. They are fairly easy to get parts for. The Cayo brothers still make fiberglass parts for them, so you can get OEM vent covers, rock guards, etc.
- I would not be doing a frame off restoration. Will I be able to access the water lines etch?
Similar to an Airstream, everything is enclosed. You have to pull the belly pan to get to the water lines. It's not a big deal at all. Just drill out the rivets, drop the pan, and you can get to everything.
- Assuming that I find a unit without AC is that a particularly costly or difficult addition - given the need to run power and a condensation line?
Avion never had a condensation line....they just let the water drip off the roof, down the along the side drip rail, and off the back corner. No harder to put an a/c unit on one of these than anything else. I changed mine out to a bigger 15,000 btu unit. Hardest part was lifting that big ol' hoss up onto the roof by myself. No problems here.
- I would use the unit for boondocking. Is it difficult to add additional gray water tank or holding tank?
Mine already had both. Shouldn't be any worse than on anything else. Avion's frame rails are deeper than Airstream's, so if nothing else, there's a little more room in there to add a tank.
- are the old stoves salvageable?
How old? My '87 Magic Chef works fine. If it was a '67, I'd probably throw it over the hill and get a new one. But you could probably get an LP gas place to fix it up for you. Truth is, they don't get used much. So it'd probably be age more than wear that has the old stove looking bad. Talk to your local LP gas outfit, especially if they modify stoves to go from natural gas to LP and vice versa.
- any other pointers?
The mid 80's models had bigger windows which made them brighter inside. The older Avions were kind of dark inside...at least for my taste. They are a very well made coach. They are very similar to Airstream, with the biggest differences being (A) Much stouter frame (B) use of more industry standard accessory parts (C) suspension not using the rubber stuff that wears out.
The only real negative I see on Avion is that they annodized their skins. Now, that is a plus as far as corrosion proofing goes. The negative is that, while you can use ParFe wax and shine one up enough to comb your hair in, you can't get a mirror polish on it like you can an Airstream with their ALCLAD skin. Now, to maintain an Airstream's polish like that, be prepared to put in a couple hundred hours a year on it. They are beautiful, but most folks don't go to that much trouble. If you can live with being able to see yourself, but not tweeze your eyebrows in the reflection, you'll be OK with Avion's finish
If you have to have a perfect mirror, better stick with Airstream.
But in the end, stouter frame, good suspension, very nice interior cabinetry, you won't go wrong with one.
Here's my 34X behind the Dodge. We like it.
Hope this helps,