Avion truck campers - Hundreds of photos

[67avion]

Without going into too much painful detail, we had a mishap several week-ends ago. While working with sand bag crews on the Mississippi River, the truck and camper fell into the flood waters as a road collapsed. Because of a number of issues dealing with the wrecker truck, we had to release the camper as the truck was reeled up over the bank. The good news is that the truck is as good as new after a thorough rinsing, inspection of brakes, etc. The bad news is that the camper was thoroughly drowned. A lot of people had far worse trouble than we did, so we consider ourselves lucky. The floods are ongoing as I write.

Our planned trip to Montana in June is called off. heh.

However, I have now convinced my dear Jane that its time to really update the TC. After drying for several days we pulled out the interior. Amazingly the Zolatone paint that I had applied last year is good as new after a cleaning.



Without burdening the TC family overmuch, I'd like to ask some advice other than don't park too near a flood :-).

My DW was overjoyed that I had a plan for the bathroom: a composting toilet developed by Nature's Head http://www.natureshead.net/. Our holding tank was practically unusable and there was no real grey water tank on the 67 Avion. Our plan is to rip out the bathroom and install one of these and converting the blackwater to a greywater tank. Any experience with this?

Finally, the roof. I admit that I have not really done the work I should have. Now, I need to remove the various sealants on the roof and repair it. We are also setting up for a solar installation. Any advice as to this?



Here's hoping I have posted the pictures correctly. And many thanks in advance for your advice.

[rastaman33609]

Silver... I did it the lazy way...I drilled out the bottom rivets and a few of the vertical ones on the interior skin, then pried the skin up enough to reach in behind it. I cut strips of wood about 1& 1/2" thick then screwed down through that into the ply. I didn't get the bite into the bunk wood I would have liked as its only 1/2" so I also made some L brackets out of 2" aluminum for the sides and riveted them into the vertical channel and screwed down into the ceder planks.

For the front I ran a strip of 2" angle aluminum long enough to span the distance under the window. It was then attached again to the vertical channel on either side of the window and multiple screws into the ceder planks. Nice and strong now.

For the wings, with the wood inside the channel I was able to get a good bite through the 2 layers of 3/4' ply using 2&1/2" screws.

I rechecked the interior lights and running lights once more before riveting things back in place.

[D1trout]

Operator error! Pls see my later post...

[ticki2]

garryk6 wrote:
Jack mounts are my tiedowns

x2

I drilled a hole through the gusset of each jack mounting ell bracket .You will have to check if the tie downs have clearance with the truck bed . I am mounted on a flatbed so a little different than a pickup bed .

[SilverPompadour]

Thanks Cajun, but Im not sure which voids you are referring to(there are so many). I had intended to leave the gaps where the ply panels insert into the channels on the bunk and wings. I was also going to add some type of 'scupper' drain to these channels to allow the water to exit. All the edges, seams and fasteners of my panels are sealed with total boat and Trempro 635. Almost the entire bunk was glued using the epoxy as the temps here have dipped below the working range of wood glue. Its looking more and more likely that I will fully coat the panels with epoxy before interior reassembly.
The interior will definitely be a non vintage custom install. If I can utilize the original ceiling mount cabinets without a large visual mismatch between old and new, I will. If not they will be up for grabs.

Rastaman you're coming along nicely as well. My interior skin had to be stripped to gain access to the fridge vent, ac and stove vent rivets and clearance light wiring. Most importantly on my C11, it gives access to screw down through the wall channel into the bunk, wings and floor. How did you get to these fasteners when doing your bunk install?

D1, I think thats a good approach, sounds like it might even be... fun?

67, Thanks for the history. It provides motivation and reinforces my belief that this is a worthy project. Looks like your baby is in good hands.

[garryk6]

Jack mounts are my tiedowns

[rastaman33609]

(Sorry cant seem to be able to post more than 1 photo at a time)

On top is another sheet of 1/2 ply once again epoxied and painted




So.....I have a question...My wings are complete, before I go any further. What are you guys using for tie-down points. Are the jack stand brackets being used or do I need to install separate tie-down hooks?

Could I used an 'eye bolt' for one of the jack mount bolts. My stands are going to be bolted through 2 sheets of 3/4 ply with a piece of 1/8th aluminium plate between jack and the body on the outside.
Inside the bolts go through alum plate also.

[rastaman33609]

Silver....man you have that thing torn apart,re assembly looks good.

This is my bunk area....that is 1/2 ply that was epoxied them primed and painted grey with oil paint. Then I used 1x8 ceder boards, in the gaps I placed insulation board.

[cajunavion]

Howdy!
Silver, way-to-go, nice work! I would add, fill
in all those potential voids, or water will pool there. The insulation
will trap it between the plywood, and well, then it all begins
again. Foam works well, except it is hard to control. You could
seal your panels with epoxy as well.
Do consider a modern interior situated to your tastes, not being
a slave to classic vintage, after all everything can be new again.
Michael showed us that.
How's it go D1, pictures?!!!!!!?
D, could we get a pictorial on your solar system?

[D1trout]

67, I'm glad to see a picture of Chuck Cayo, our link to the illustrious history of these TC we obsess over! I hope he is able to sort out your issues. Nobody knows them better than he.
Onward!

[67avion]

I took my damaged Avion back home yesterday. We traveled to Watervliet, Michigan, where the original Avion trailers and TCs were manufactured. Later Avion expanded to several cities in the West during the height of their popularity. But this is the mother ship.

Chuck Cayo met us at his shop. That's Chuck on the right.



We examined the issues on the roof where the solar panels had been ripped off. We also discovered a lot of problems with the electrical system where shorts had jumped from spot to spot after the solar panels had been damaged. We still don't understand why the fusing didn't stop the wires from burning. It appears that the hot water heater is fried as well as the Wave3 catalytic heater. I think I'm lucky the whole thing didn't burn.

Chuck Cayo inspects the roof.



Outside was an historic Avion TC. It was used by Ford Motor Company when they designed their "Camper Specials" in the early 70s. According to Chuck, Ford wanted a camper that wouldn't fall apart during their arduous track testing. Apparently several other TCs had collapsed. Not only did this Avion survive the 250,000 mile test program, it still is still being used.



I am confident that Cayo can handle the damage to my coach and we'll be camping again.

It turns out the road to Muley Point runs through Watervliet, Michigan.

[D1trout]

Silver, as I've thought about the process today, I recall that I made rough pattern pieces by laying construction paper over the petals on the outside corner, tracing the shapes, cutting those shapes out and then taping them into the inside corner. Then adjusting those shapes until they were accurate. Then tracing those shapes onto mat board and finally fitting each mat board piece carefully. The same pattern pieces seem to work in all four interior corners.
Dick

[SilverPompadour]

Thank you both. I'm embarrassed that I missed that write up, amazing work ticki2. Couldn't find it at first, page 266 cause of my 'sort order'.
The freakish weather here has helped me keep a good pace on the project. At this rate, the Avion might make Toroweap(my Muley pt.) this spring.

[D1trout]

Silver, I removed the molded plastic endcaps at either end of Argo and using mat board, fabricated petals that are very similar to the exterior corner petals. These mat board petals are my pattern. It took me about a day of fiddling to get a set of well-fitted pattern pieces. When I get everything wired and insulated, I will cut aluminum pieces using the pattern pieces. I intend to rivet them onto the ribs. I am hopeful they will be neat and attractive. The plastic end caps don't do much aesthetically...
You ARE making good progress. Onward!

[ticki2]

Take a look at page 54 on this thread . I made some aluminum panels similar to the exterior because the plastic was kaput .

You are making good progress .

[SilverPompadour]

Not quite ready for the interior yet but wondered about some ideas for the rounded plastic panels front and rear. Both of mine are in pieces, some big, some small, but I think I have them all. Sorry if I missed this in a previous post.