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Old 02-11-2015, 08:28 AM   #21
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1955 22' Safari
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According to another post I read the interior panels are just pop riveted. If so, I can remove and reinstall panels but where did you find polished 5052 for that price? What thickness?
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Old 02-11-2015, 08:33 AM   #22
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Zolatone end cap

These do not look like pop rivets to me...
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Old 02-11-2015, 09:46 PM   #23
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Check out "polishing airstream with 12" insisel wheel" on you tube, he has a method, which I use, where you use a 7 1/2" variable speed angle grinder at 3000 rpm with the black or brown compound bar for the first cut or compound. You just deburr the wheel every once in a while. I've got about 60 hours on my roof so far... had to do it while I had scaffolding available. I went to Caswell to get everything. First I use the black... haven't even bothered with brown bar, and then used a white bar, and then to Nuvite F7 I believe on the cyclo. Came out great. I would recommend just a 4" wheel on maybe a drill for the inside, as it's a more tighter spot.
The reason I'm going this route is I have fiberglass endcaps, but I'll be polishing the other areas that look ok, if Not I'm going with Melody on this and using 5052, for the pieces that are bad, and/or maybe the rear section or something.
I've done so much work, I think I may have just been better off to replace. Many say it looks nicer, and was much easier. But I'm cheap.
Even if they don't come out perfect, I can still use them behind cabinets and what not. Still don't have final interior design figured out.

Bambi Tex - Those don't look like pop rivets, and I'm not sure what they did on a '64.
I have a '65 and it has fiberglass interior endcaps. You could always drill a couple out and see if they have a shank I guess. If I had aluminum endcaps I'd just try and strip them. I have a feeling rebuilding aluminum endcaps is going to be a little tricky.

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Old 02-12-2015, 06:46 AM   #24
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The pic is of my 54/55 Flying Cloud end cap. Sold the Bambi.
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Old 02-12-2015, 08:59 AM   #25
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Melody, so funny, I was just thinking last night as I was staring at my stripped ceiling panels how much easier it would have been to refab them. But not sure where to find 4'X12' sheets. I definitely will look at replacing some of the smaller panel...especially the heavily corroded ones. Still thinking I may leave the Zolatone where it will be hidden by cabinetry etc.

Bambi, my aluminum end cap in the back had all pop rivets except for 2 rows in the middle which had bucks. Random...think they just ran short of pop rivets in the factory that day and I plan to use all pops to put them back together (holes are the same). All the rivets in the middle just hold the panels to each other so you don't have to remove them to remove the end cap. I took mine apart to make them easier to strip and so I wouldn't have to clean the old rivets. But the end cap panels did not lay flat and I think they would be very tricky to refab.

And if you haven't tried 0000 steel wool instead of the scotchbrite you might give it a try...I guess you're going for a cloudy finish anyway but the 0000 cleans better I think.
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Old 02-12-2015, 04:18 PM   #26
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Bambi Tex- on a 55 those could definetly be buck rivets.

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Old 03-01-2015, 12:30 PM   #27
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Just got my end caps and two big ceiling panels back in. You can see from the pic that I only polished the areas of the end cap that would have had me polishing upside-down after install.

I did the same process on it all. After getting all the paint and residue off, I did 2 passes coarse, and medium polish with the rotating polisher and 2 passes with Grade S with the Cyclo. Areas of the end cap came out stunning. The ceiling panels look good, but not as stunning. The only thing I did different was some wet sanding on the end cap panels. Maybe the ceiling panel didn't have the alclad?

Anyway, I am really going to try and avoid any more Zolatone stripping. Most of my panels are too corrupted to look that good after restoring and it's just too much work.

Also not going to polish in the garage anymore...despite tarps etc....the black oxidation got everywhere and even with a 'no shoes in the house' policy, somehow the black found it's way in leading to some serious wife-rage.
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Old 03-01-2015, 03:59 PM   #28
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Looking sweet, I hope my portions that will be polished come out that nice.
I have yet to "Finish" them. Stripping done, but not polished.
I understand on the "Black" stuff.... everywhere I tell you, everywhere.
I ended up getting a cloth head covering, otherwise I had it all over my face.

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Old 03-05-2015, 11:57 AM   #29
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I am getting ready to head down to my local sheet metal shop to have them cut me some replacement panels. They stock 5052 4X10 sheets, "mill finish" with vinyl on one side. The .032 is $35/sheet and the .040 is $45/sheet.

I am assuming .032 is fine right?

They say they can order polished 5052 but it's more $$$ (not sure how much more). But much of these lower panels will be hidden behind bunks and cabinets so I won't polish it anyway.

They can also order 4X12 pieces to replicate my street side panel that is 4X12.

I welcome any advice before I set these guys to task. Can't wait to not scrape Zolatone with a respirator and sweaty rubber gloves for hours on end!
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Old 03-05-2015, 02:17 PM   #30
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Well, if your not too concerned about a "HIGH" polish, then the mill will be fine.
I would assume .032 should work, but others can chime in.
I think the 5052x.032 in mill would look like a modern airstream, and won't show as much streaks when touched by visitors.
I'll be using the 5052 x 0.40 for my belly pan just to add more protection for possible projectiles during travel.

If you want the polish like your rear, then go with 2024T3x.032
That's what I've used for my exterior panel replacements, and will use for my front interior endcap overlay.

Others may want to chime into to the type of 5052. I want to say 5052H3 is what is used mostly, but again, I have not done that yet.

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Old 03-07-2015, 06:21 PM   #31
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So a 4X10 sheet of 5052 with vinyl on one side ended up being $50. The finish behind the vinyl looks like a "modern Airstream" as Redsled notes, but I think it will polish up pretty good based on some patches I have done.

The prices I am seeing online for 2024T3 or polished 5052 are extreme and I didn't even look at the shipping. Nobody seems to carry it around here.

I got some metal cutting wheels for my skill saw and that is working well for the long cuts. Worked through 2 sheets today and will need 2 more plus a 4X12 for my long wall panel.
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Old 03-09-2015, 11:12 AM   #32
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Metal Wheel

I have been using a cheap pair of air sheers for my cutting, and hand snippers for little stuff.

Haven't tried a metal wheel yet, may make a rough cut.

Is it 5052H3x.032? I think you could get a nice finish. May take more work to get "Mirror" like 2024, but easy to get a nice finish

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Old 03-10-2015, 12:10 PM   #33
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Yeah, I should probably get a compressor and some air sheers but at this point I am almost done. Making the rainbow arc cuts over the wheel wells is going to be the hardest.

The skill saw with the cutting wheel is a bit rough but I can go over it with the angle grinder for a pretty good result.

The original skins measured in a .032 but somehow they feel thinner and flimsier than the new sheet.

I got 4 more to go and then I'll post some pics for anyone still interested.
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Old 03-11-2015, 12:37 PM   #34
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I think Harbor Freight makes a cheap pair of electric sheers, which may be an easy option for the rounded parts.

Can't wait to see the pics!
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Old 04-20-2015, 08:39 AM   #35
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Birch end caps

Another option is birch paneling...
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Old 04-23-2018, 07:20 PM   #36
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Zolatone is winning

Thank you for all of the experience and advice shared here. I am in the middle of stripping the Zolatone from the end cap. My shoulder muscles are pretty sore.

The pictures of the results of your work are inspiring. Maybe waiting until it warms up a bit more and using scotch bright pads will speed the process a bit. The attached picture represents about six hours of work spread over a few sessions.
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Old 04-24-2018, 07:22 AM   #37
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Hang in there! It's been a while now for me and all the hard work and drudgery is a distant memory. I camped almost every weekend this winter up in the snow and would wake up each morning appreciating my polished interior. And my kick ass insulation! Even in single digit temps, my heater barely has to kick on! Now I've got to solar panels mounted on the roof so I never have to worry about the battery. Everyone else is running there stinky generators all day.

Life is good!
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