The Airstream Diary

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Archive for the ‘ Full Monty ’ Category

All the Trimmings – Airstream Trim Pieces and Banana Skins

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#airstream #airstreamrepair airstream trailers airstreamers airstream trailer repairs aluminum banana skins

 

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It’s almost as bad as fly fishing – the crazy names Airstreamers come up with for pieces and parts of our beloved trailers. If you were wondering what a “Banana Skin” is, it’s the curved piece that goes around the corners between the side skins and the belly / belly pan area.

As you can see, when your Airstream comes to you with someone else’s battle scars, or invasive surgery scars, you have want to do the patching that accomplishes two important things – keeps the rodent population at bay, and keeps the water from having an easy entry into the bottom of the trailer.

As much as we would like to think we are building our Airstreams in the likeness of our houses, I have come to find that it’s better to think of it as building our trailers to be “super tents” instead. I have spent enough nights on the ground, in a tent, in the rain, in sleet, in snow … that an Airstream is a long way up the chain from the tent days, in my new-found opinion.

We not only put the banana skins back on the trailer, we also:

– gently beat some of the dents out of the leading (front) edge bananas — that came from rocks

– patched the bananas

– cleaned the Airstream trim pieces – BACK and front before riveting them in place

– coated the edge of the “belly board” – that will he holding the new fresh water tank – with epoxy

– riveted all the trim (between the bananas and side / the side and around back) back into place (It’s the lower trim piece

That lower trim piece has several functions, and a certain way I seemed to think made it go back on better.

The turns are where a bent, or protruding trim piece will show most, so that is where I started my rivets – securing the turns, and then coming around to the sides / front / or back flat runs. There were places with significant gaps between the trim and the side of the trailer (not so much along the straight runs). And those places seemed to be caused by the body skin being dented at some time, perhaps during the full monty. So we got back inside and took a soft mallet to actually hammer the skin back out to a natural position that closed the gap. Makes sense.

TRIM YOUR RIVETS

Another thing that makes sense is to trim the rivet if you find them getting too close to a raised edge of the trim piece. As you see in the photographs, just take a pair of metal cutters, and trim the edge that would otherwise keep the rivet from being flush. For whatever reason, be prepared to have two different size rivets along the way as well – and make them the “Medium” length while you’re at it. Those holes can start off different sized, or after 43-years, they can end up different sized … can’t we all?

SEAL THAT EDGE

Sealing the edge of the plywood that goes on the belly of the trailer makes sense because it will be (indirectly) exposed to all the elements we find on the road. Once the plywood is dry – hardened fiberglass resin – I will finish the piece with a thin piece of aluminum or galvanized tin sheet metal to prevent road damage. YOU HAVE TO IMAGINE all the things that will be hitting the bottom of your trailer along the way, and although it’s a thick piece of plywood, that last cladding of the plywood makes it bulletproof.

BE A TRAILER

I try and imagine myself tied to the bottom of the trailer, face down, facing the road. That makes me think about all the things coming at the trailer – rain, rocks, snow, low clearance crossings and all the things we see on major roads these days. Just go with a worst case scenario, and prepare the bottom of your trailer for that – that should do the trick. Cladding, the skins, a good seal, all of these things are what we do to prepare the trailer itself. From there, later on, we prepare the vehicle to minimize what it throws a trailer’s way, but that’s another story for another day!

 

 

 

Another Day at the Airstream

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Images from another workday at A&P Vintage Trailer Works.

Stuck and Unstuck

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Looks like we are still stuck at GO as far as the Marmoleum issue goes. Just wish we had gotten it right to begin with. I am trying to avoid calling the Marmoleum a “worst case scenario,” but that’s where we’re headed – cost and appearance. Once I can bring myself to think about this entire episode, much later in life, I will go back through and tell you what all went wrong, and how you can avoid my mistakes.

CAN’T GO UNDER IT. CAN’T GO OVER IT. HAVE TO GO AROUND IT!
However, I finally decided to bypass what I thought would be the normal order of things, and am fast at work – bolting down the trailer, and working my way to the back where I had to remove rivets to the back center outer skin – in order to get the uniquely angled steel piece to go in AND MOST IMPORTANTLY – be Sikaflex-ed and bolted down – through the U channel, through the flooring, through the plywood, through the skeleton piece of steel angle that was abandoned and through the new back crossmember. Also found that the bottom edge of that back inside skin had corrosion progressing quickly (remember the tail rot?). So that will have to be backed or fronted with a new sliver – the location is just below the back hatch if you are playing along.

FRONT END CAP
The front end cap is out. That revealed another tiny skeleton – this one a lizard. Removing the Airstream end caps also lets you get a look for evidence of leaking, and test for water leaks before you put it all back together. That funky Airstream smell is just about gone, and I think these last vestiges of pink fiberglass insulation will be the final hint of “that smell.”

Starting at one end and working to the other is the way you want to check leaks and go back together. In previous weeks / months rains, I found a freight train of water running down outside the diagonal seam in the front end cap, and straight under the window frames of both curved front side windows (note photo of aluminum tape which diverted the flood). It was a non-stop torrent. The process for removing those windows is to first TAP the centers of the rivets, and second – drill out those rivets. The windows are still in, but according to Paul, they are jinked behind the frame of the front center window to some extent, and the final remove takes some real strong sensitivity (how’s that for an oxymoron!).

The end cap itself is in perfect condition, and will need some custom woodwork for the opening that had the gauges and speakers, as well as a new door on the wide compartment that is at the bottom of the end cap (below the gauges and all).

I CAN SEE CLEARLY NOW
Leslie has done a quick and fantastic job of replacing the gaskets around the windows, and is down to her last window which just needs to have the new foam (D Pattern) stuck on (came pre-backed with sticky covered with peal off paper backing.

NOTE – I shot some video of work done to prepare windows for new D Gaskets. If you want to see it, let me know.

Work Gets in the Way of Work

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Ahhhhhhh! I forgot and left the Airstream home alone (actually at A&P’s) for 45 days!

Finally made it back out to Cottondale, Texas, today. It’s been so long I may have to remind you that is where the Safari 23 resides, among many more Airstreams at A&P Vintage Trailer Repair, aka. Ann & Paul’s.

I described the feeling to Ann as what I would imagine a parent to feel when they look up two months later, and remember they forgot to pick their kid up at school. You hope they are still there.It felt like the inanimate Airstream was a little upset being left out there in the rain, wind and hail. Thank goodness we have so little of all of those in North Texas these days. Global something, you know.

As many steps as we made forward before the work hiatus (when I actually went to work), I also took a couple of steps back, and they feel like they were knee-deep into mud. First, the angle iron (custom bent as you recall) that runs along the back wall – sandwiched between the wall and U channel – had to be cut out with the plasma cutter. It didn’t line up properly AND I had already sandwiched the bottom of the angle between the floor and the frame with liberal amounts of that bonding calk. Done, cut out and gone. SECOND, the perfectly straight runners that go underneath along the outriggers (they are where the belly pan and outside wall panels curve under, meet and get riveted), no longer line up the same distance in as they did on the original frame. Rather than cut those out, I ordered a whole new run of them, and they will run doublewide down the length of both sides of the trailer. None of that would be a big deal, but I am the guy who hates rust. That means everything that has been cut out was already painted – well painted. That means I now have to paint the runners, crawl around on the ground with a welder, and act like a weldor again. I hoped I was done with that, but NOooo.

On the cooler side, I did order our new Dometic air conditioner today. We went for the biggest they have, since it is Texas after all. I should have that in a couple of days.

The checklist gets longer not shorter now.

There’s still the sheet of plywood that supports the freshwater tank. Somebody remind me why I threw the old one away. It’s a funny thing. This sheet of plywood really needs to be bullet proof. It covers a huge area of the bottom of the trailer, is exposed to all the elements we will be navigating (think Stony Pass water crossings), and it supports a lot of weight. What a recipe. The original wasn’t in too good a shape, but it did appear to have the sheet of aluminum adhered to it quite well – almost like another layer of plywood veneer! So, I have to bomb-proof that piece of plywood.

We also have a buckle in the marmoleum flooring that runs in a visible spot. The floor laid out fine before we dropped the shell back on it, but now with heat (or whatever) it is a serious problem. It looks like we will have to cut a splice in the marmoleum, gather and glue it.

NOTE – Just to give you guys the heads-up, I am about to pump some serious energy into this website. You will notice a “Instagram” photo in the sidebar, and a twitter feed as well. I have put off really “plugging in” this site until I was ready to deal with what it means for readers and traffic here. If you ever see anything you don’t like, let me know. I AM ALSO MAKING IT EASIER TO COMMENT on this site. You can comment and ask questions without having to register or login. Your comment will be held for approval, but that’s only prudent.

I am also undertaking the redesign of Ann & Paul’s site this summer. So keep your eyes on www.apvintagetrailerworks.com in coming weeks.

Video of Redressing of Airstream Safari

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Here’s the video I shot of the shell going back onto the frame. I was using a new GoPro camera, and they are quite finicky cameras. This time, it froze up before the process was complete, but you can see kind of how things work during this process. It was complicated a little by the wind, but basically other than a few screws in the C channel that had to be removed before dropping the shell on, it was a clean drop. The audio is from the internal speaker, which is encased in a waterproof case. That equals bad sound, but since the video was corrupted, I didn’t even bother to do a voice over. As soon as the Airstream videos get better, I am sure I won’t be able to resist hearing myself on a voiceover.