The weather is really hampering my progress... rain & cold in July. Feels like winter is coming. So... been working away at the upholstery (another new skill learned so far during this process).
Here's a couple photos of the driver's seat so far... my first attempt. I added a lot of new foam (an entire 2' x 4' block actually), and the cover is a little too large, but I think the next one will fit better. Either way, looks much better than before.
Here's a couple photos of the driver's seat so far... my first attempt. I added a lot of new foam (an entire 2' x 4' block actually), and the cover is a little too large, but I think the next one will fit better. Either way, looks much better than before.
Slowly, but surely, progress continues. Most of the frame around the driver has been replaced, and now the aluminum and fender back on. Next the door and window go back in and then I can move to the rear of the motorhome.
I used liquid nails polyurethane to glue the aluminum sheeting to the frame. Next I'll set a few rivets to make sure it doesn't come apart. Inside I'll be using foam, which will also stick to the inside of the aluminum and help to keep it in place. The steel I used for the framing was 1/4", much thicker than the original steel tubing. I also added some bracing and sistered in some steel in other places to really strengthen the entire area.
lots of new steel
fender back on
I used liquid nails polyurethane to glue the aluminum sheeting to the frame. Next I'll set a few rivets to make sure it doesn't come apart. Inside I'll be using foam, which will also stick to the inside of the aluminum and help to keep it in place. The steel I used for the framing was 1/4", much thicker than the original steel tubing. I also added some bracing and sistered in some steel in other places to really strengthen the entire area.
lots of new steel
fender back on
Ok, so it's been raining quite a bit making it hard to work on the frame, which is almost finished in the front (pics of that soon)... so some inside work... I've started re-upholstering the front seats and the front dashboard.
Found a really great deal on some good vinyl on ebay. 15 yards shipped to my door for $45. It's an off-white naugahyde with a nice texture (hard to see in photos). It's sewing easy and gluing to the dash quite well. It'll take less than $100 to finish the dash and both front seats.
Here's my first ever attempt at reupholstery (front seat chair arm). I think I got it a little tight, but the next ones should turn out better. I originally wanted to use suede where the lighter material was on the old arm rests, but because of time, price and no experience sewing/reupholstering I decided to keep it simple
Here you can see the texture (grain) of the vinyl better. I'm very happy with it. I still need to exacto out around those screw pegs so the vinyl pops up flush with the name plate.
More angles
On a side note, the molasses rust removal experiment on the propane tank seems to be a huge success. The entire tank is black, from what I assume is basically converted rust. I have two more days until I pull the plastic off and see for sure, but it certainly looks promising.
The front box frame is almost completely replaced with much stronger steel (1/4" instead of the original 1/8"), and further reinforced.
The front end is getting a complete makeover. I'm swapping out the 80s square headlamps for two custom round lamps on each side. The hood is getting a new shape which will tie into the lights and a new bumper skin made from fiberglass. I'll put up pics of the entire process after it's complete.
The dash is getting new vinyl, and the black insert which houses all the buttons and gauges is getting a wood finish treatment. I'm also replacing the gauge backs with custom white inserts.
Found a really great deal on some good vinyl on ebay. 15 yards shipped to my door for $45. It's an off-white naugahyde with a nice texture (hard to see in photos). It's sewing easy and gluing to the dash quite well. It'll take less than $100 to finish the dash and both front seats.
Here's my first ever attempt at reupholstery (front seat chair arm). I think I got it a little tight, but the next ones should turn out better. I originally wanted to use suede where the lighter material was on the old arm rests, but because of time, price and no experience sewing/reupholstering I decided to keep it simple
Here you can see the texture (grain) of the vinyl better. I'm very happy with it. I still need to exacto out around those screw pegs so the vinyl pops up flush with the name plate.
More angles
On a side note, the molasses rust removal experiment on the propane tank seems to be a huge success. The entire tank is black, from what I assume is basically converted rust. I have two more days until I pull the plastic off and see for sure, but it certainly looks promising.
The front box frame is almost completely replaced with much stronger steel (1/4" instead of the original 1/8"), and further reinforced.
The front end is getting a complete makeover. I'm swapping out the 80s square headlamps for two custom round lamps on each side. The hood is getting a new shape which will tie into the lights and a new bumper skin made from fiberglass. I'll put up pics of the entire process after it's complete.
The dash is getting new vinyl, and the black insert which houses all the buttons and gauges is getting a wood finish treatment. I'm also replacing the gauge backs with custom white inserts.
Here's the propane tank I removed. It was perfect for a test I've been wanting to try... which is to use molasses to remove rust from a large object that cannot fit in a vat (if you haven't heard of molasses rust removal google it)
I tried to simply brush some molasses on, but it dried too quickly. The next night I brushed molasses on again, but then covered it with plastic wrap. It still dried, but much slower and did turn some of the rust black, so next I'll mix 1:1 molasses to water and cover the entire thing and wrap it and check back in a week.
After I paint it I'm going to take it somewhere and have new valves installed.
The metal is rusty, but doesn't appear to be thin anywhere... I believe I can have it pressured tested as well.. if anyone has any other suggestions I'm all ears, considering it's an explosive tank.
I tried to simply brush some molasses on, but it dried too quickly. The next night I brushed molasses on again, but then covered it with plastic wrap. It still dried, but much slower and did turn some of the rust black, so next I'll mix 1:1 molasses to water and cover the entire thing and wrap it and check back in a week.
After I paint it I'm going to take it somewhere and have new valves installed.
The metal is rusty, but doesn't appear to be thin anywhere... I believe I can have it pressured tested as well.. if anyone has any other suggestions I'm all ears, considering it's an explosive tank.
Well everyone, progress continues... slowly, but surely. The inside is almost completely gutted, and the driver's side wall is half removed.
Something that was really bothering me was flex in the floor below the driver's feet when driving... turns out my concern was well justified, as the box frame was completely rotted out around the driver's side door in the front (see photos). The sidewall frame above the driver was also broken away from the roof frame, and the mounting bracket to the frame is fractured. The original construction leaves a bit to be desired... not much to it. Along with replacing the rotten metal, I'll be adding a bit of additional reinforcement to original structure.
I'm sticking with my original plan, although it's become more involved than I wanted (but not unexpected). At least I know this motorhome will be safe when I'm done.
Since these photos were taken I've replaced most of the frame around the front driver's side. The subfloor in the rear of the MH also has rot, and I will be replacing all of the cross-members with new metal back there as well.
After the box frame is rock solid all around the coach I'll continue with the mechanics (been doing some here and there anyway). Then I'll replace the roof, take care of exterior cosmetics and paint, and then build the interior.
Down to the box frame
Completely rotted and broken away. Only thing holding this together was the exterior sheeting and the door frame.
One of 3 main structure breaks causing the motorhome to flex when driving
The sidewall popped out 2-3 inches from pressure once the sheeting was removed.
Here you can see how far the sidewall pushed out. Should be flush with the metal plate on the right (is now that it's repaired).
Bottom frame in rear. Will be replacing all the bottom side rails and all of this cross members. Bolts lag through the floor joyces into these steel tubes, so I really wanted to be sure they're solid.
Something that was really bothering me was flex in the floor below the driver's feet when driving... turns out my concern was well justified, as the box frame was completely rotted out around the driver's side door in the front (see photos). The sidewall frame above the driver was also broken away from the roof frame, and the mounting bracket to the frame is fractured. The original construction leaves a bit to be desired... not much to it. Along with replacing the rotten metal, I'll be adding a bit of additional reinforcement to original structure.
I'm sticking with my original plan, although it's become more involved than I wanted (but not unexpected). At least I know this motorhome will be safe when I'm done.
Since these photos were taken I've replaced most of the frame around the front driver's side. The subfloor in the rear of the MH also has rot, and I will be replacing all of the cross-members with new metal back there as well.
After the box frame is rock solid all around the coach I'll continue with the mechanics (been doing some here and there anyway). Then I'll replace the roof, take care of exterior cosmetics and paint, and then build the interior.
Down to the box frame
Completely rotted and broken away. Only thing holding this together was the exterior sheeting and the door frame.
One of 3 main structure breaks causing the motorhome to flex when driving
The sidewall popped out 2-3 inches from pressure once the sheeting was removed.
Here you can see how far the sidewall pushed out. Should be flush with the metal plate on the right (is now that it's repaired).
Bottom frame in rear. Will be replacing all the bottom side rails and all of this cross members. Bolts lag through the floor joyces into these steel tubes, so I really wanted to be sure they're solid.
