Starcraft Travel Star Restoration

A 2004 Travel Star is laminated panel construction including the floor, and dealing with the laminated construction is not anywhere close to being simple as just replacing "sheets" of plywood. It can be done, and has been done, but it's not exactly easy and involves adding a lot of additional supports, as the aluminum structural supports in the panels are placed far apart. The top layer of the floor under the vinyl flooring will be nominal 1/4" (around 3/16") and the bottom layer 1/8" with 1x1-1/2" aluminum tube on 32" or wider centers with nothing between but 1-1/2" beaded foam. On the wall panels they'll have 1/8" plywood inner and outer with 1" tubes and foam between, those tubes could be 4' apart or further with no framing whatsoever around openings.

Thank you for your info, all is helpful.. It came in the yard Friday night, and won't even be able to get into it till Monday. I'm hoping the floor damage is only under the front, seating/sofa area, but since the walls and ceiling also have water damaged I'm expecting the worse. The running lights are also running intermittently, on off, might be a bad wire or the plug itself, no way to tell yet. Have no idea if any of the appliances are working, A/C, heater, etc. So, on a wing and a prayer, hoping we can get it done by next years(2019) Sept. vacation. Hope we haven't bitten off more than we can chew..

take lots of pictures

stevemorris wrote:
ive replaced major sections of floor in two trailers(no wall damage)
its not difficult.

start by removing all of the appliances and cabinetry. some plumbing may have to be cut and rejoined later. upper cabinets can stay but its easier to wrestle large sheets of plywood in there if the're gone

remember the interior and exterior walls are built on top of the plywood floor you are replacing and if the subfloor is rotten under the walls it must be replaced

I had two bad spots in the original floor. I was able to cut or grind any fasteners that secured the floor sheet underneath the walls. I cut new pieces of plywood and slid them back underneath the wall frame. I also relocated the toilet in the bathroom so that flooring sheet was replaced, as well.

That's one of the really nice things about restoration, a guy can move things around so that the trailer better fits the owner's needs.

ive replaced major sections of floor in two trailers(no wall damage)
its not difficult.

start by removing all of the appliances and cabinetry. some plumbing may have to be cut and rejoined later. upper cabinets can stay but its easier to wrestle large sheets of plywood in there if the're gone

remember the interior and exterior walls are built on top of the plywood floor you are replacing and if the subfloor is rotten under the walls it must be replaced

You will find out the extent of the damage after you have walls opened and floor uncovered.

FWIW, I restored a '71 Wanderstar, full gut out and rebuild. It too, had framing and floor damage from water leaks. It took me 6 mos. of nearly full-time work to get it all done right.

My flooring is 5/8" CDX plywood attached to wood joists. I'm not sure about Starcraft's construction material evolution. You will find out what you have when uncovered.

If you need process-specific answers, PM me with details or post in this thread. FWIW, I'm a semi-retired Residential Building Contractor.

Most restorations involve tedium. That is the sweat-equity payment you make. Commit to a longer than anticipated work schedule and don't lose momentum. There are a lot of gutted and never completed project trailers out there. Good luck!