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April 6th, 2009, 11:40 AM
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#1
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Fleetwing Camper Build
Re:: The Classic Car Motel
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April 6th, 2009, 11:43 AM
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#2
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Join Date: Mar 2007
Location: Fleetwood, PA
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Re: Fleetwing Camper Build
Once I got it home (early fall 08) it needed some cleaning. Here is how dirty the outside was!
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April 6th, 2009, 12:07 PM
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#3
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Join Date: Mar 2007
Location: Fleetwood, PA
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Re: Fleetwing Camper Build
Well I had no time over winter to even look at the camper. We took it up to Austin's (Scotty Restorer, who is helping me) last fall (late). It sat outside beside his garage just waiting for me. Well we finally made time for it this past weekend (April 4, 09). I'm am early riser and so it Austin. We pushed her into the garage around 7:30am. We have already talked about what is planned for the future so we were both on the same page. It was planned to keep digging til we hide SOLID material! then start building from there.
We lucked out that it was all screwed together, Scotty campers are all build with the spiral nails. Try pulling those out without dinging the alum. siding  ! A 1/4" socket on the drill and off we went. Keep in mind this is my FIRST camper build, so I'm excited to start ripping into it. So let the build begin!
The siding came off from the bottom up.
All the alum. siding and fiberglass are off both sides. Now starting to unscrew the front, roof & back siding (all one piece 4' sections seamed together)
Needed a place to put the roof section without dinging it. So we hung it up!
Here is some of the water damage that happens from leaking seams and misc. nail holes.
The roof above the door way.
The front and back has been taken off.
Now down to the floor. The walls had to be taken off to put the new flooring on. This is where we left it 4:00pm
We looked at everything and measured some stuff. It was a good stopping point for a great days work. It was time for a beer! Tomorrow is another day.
Last edited by Scott76; April 6th, 2009 at 12:36 PM.
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April 6th, 2009, 12:16 PM
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#4
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
Sunday morning 8:00am. We looked at the floor and had a little talk and started to rip up the UGLY flooring. It was a little hard and the wood subfloor was very soft in the corners so up it came. It was a good thing because there was some big black ants in the plywood floor. We took in down to the metal trailer frame.
Like I said before. It was getting ripped down till we hit SOLID material!
Now it was rigged to be towed home with me to get the metal up to standard and finished. So now its home with me and getting ready to get sandblasted, primered and bedlined.
Now we have a material list for the rebuild! I'm pretty happy.
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April 13th, 2009, 04:06 AM
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#5
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
We had another weekend. So we started on the walls. Took the driverside wall and removed the inside face to repair the studs. There was a lot of rot and we had to have a strong thought about how to go about it. Austin has a full wood working shop (lucky me)!! He planed some boards down to the thickness of the existing studs and started to rebuild them. One stud at a time.
Existing stud wall:
New stud wall:
Trimming the inside face:
Inside face done and waiting to be primered:
Now the pass. side wall was a little rougher!! We started to replacing a stud at a time. I was hoping to at least use 2 or 3 pcs. but nope. We build an all new wall. We did use the 3 pcs. of plywood in the back corner but thats it. We also beefed up the door frame. The existing was all stapled. We used screws in the important points.
The existing pass. stud wall:
All new stud wall:
Inside face done and waiting to be primered:
We had a little time before Easter dinner. So we planned some more steps and material list for the inside cabnets. We did build the front benchs that go with the table and the back of the camper/bed bench area.
I am trying to save and use existing wood as much as I can but thats a hard task! Theres not much to save. How many people can say they have a brand new 1969 camper?
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April 16th, 2009, 06:50 AM
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#6
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
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April 20th, 2009, 06:40 AM
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#7
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
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Re: Fleetwing Camper Build
I sandblasted the frame and primered it. It took sometime to get the sandblasting done. It isn't no easy job, but it needed done.
Before blasting:
I found the VIN#. I had an idea where it was but with all the coats of paint on the tongue no one would have found it. Really there was 2 places were the VIN# are at.
After blasting waiting for primer:
Here its primered waiting for bedliner:
The tongue is wrapped up to get painted white. I didn't want the bedliner on it. The orig. tongue paint was white to match the white siding. I cut all the Pressure Treated wood to finish the frame work and all the cross braces. I use a sandblasting gun (that sucks up the sand) and modified it to use with the bedliner. I punched a hole in the gal. lid and shoved the hose in and just strayed the bedline on. It worked GREAT. I'm VERY happy how it turned out.
Now I have left to sandblast is the step, axle, the rest of the hitch, my buddy's rad. support for his Nova and a little side project for me (you'll see it later). I hope to have the blasting done with in 2 days. Something about sandblasting isn't fun. I'm thinking about getting a pet monkey and teaching him how to do it!
I'm working on getting new brake assemblies. I'm going today to match up my old ones with new ones at a local trailer shop. I'm getting new u-bolts too but I'm trying to find the right size. I'm thinking of putting a 1" block under the axle to get it to sit a little lower.
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April 29th, 2009, 04:07 AM
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#8
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
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April 30th, 2009, 05:30 AM
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#9
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
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May 11th, 2009, 03:50 AM
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#10
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
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May 11th, 2009, 05:02 AM
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#11
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
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May 13th, 2009, 04:10 AM
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#12
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
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Re: Fleetwing Camper Build
Since the frame is done and up north I have time to start on all the alum. trim (door frame, windows, trim around the all the edges). It has never been touch since it was put on the camper in '69. I need to freshen it up alittle! I set up a buffing operation in the garage. It's mighty fun!
Before:
After: (not totaly finished polishing it yet, its just buffed)
Now imagine ALL the alum. trim like that!
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May 26th, 2009, 05:23 AM
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#13
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
We had a great holiday weekend and worked on the camper 4 days. It may not look like we did much but we didn't stop at all. We made the cabinets and the back couch/bed. Plus there was a lot of painting. The wife & I agreed on the color last week after several long days of trying to agree on the fabric first! Its easier to match the paint to the fabric instead of the fabric to the paint. The fabric has been ordered and already at the house. I'll post more about the fabric later.
So we painted the walls and all the cabinets. We are painting all the cabinets before we install them. It will give it a cleaner look. We made the cabinets. It is a little harder than I thought. Did you ever try to put 10lbs of shit in a 5lb bag? Its a close & tight area. No room for errors. Its one of those things you measure 3 time then write it down and then cut. Its not an easy thing to do. So there isn't many pics but we did get a lot done/made. (plus I forgot my camera).
Heres the back couch/bed plus you can see the color in the shade alot easier.
the front benches drying.
The kitchen area sink, stove top, icebox, & cabinet. It needs patched and sanded down to smooth over the front face. Need to patch the top screw holes before the formice is put down. Some of the sliding doors are sitting ontop of the cabinet.
The over head cabinet thats above the kitchen area. It need alittle patch and sanded again.
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June 8th, 2009, 06:33 AM
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#14
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
Well let me just tell you how much this sucks that this project is 3.5hrs away from me. It would have been done by now if it was at my place or I lived closer!!!
I had a full day of painting and trimming one of the holes for the tongue jack. So all the cabinets that are made are fully painted and are ready to be installed. There is one more cabinet that needs to be built that goes over the table, but that will be built in place since we are going to build a front wall and frame the front window in at the same time. I haven't touched the alum. in a month because of wrapping up some loose ends on other projects. We ordered new foam for all the cushions and are waiting on it to come in. I need to get the piping chord and fabric to start making my own piping (welting) for the cushions. Just wait til you see the fabric. Its cool!! I picked it out and the wife liked it too!!!
Anyways. The cabinets are painted and are ready to be installed which will be this coming weekend. The fomica will be on the kitchen cabinet and the backsplash. I ordered a little extra flooring so all the bottoms of the cabinets will be covered. I have always hated that sticky paper you put in there. Theres not much of the work this past weekend but I did remember the camera.
Whats a Scotty for? Thats an all orig. Highlander that has not been touched. Still have the ladder & orig. cushions. Its really nice. But I needed a place to lean my parts so they can dry!!!
My beautiful little hard worker!
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June 15th, 2009, 05:24 AM
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#15
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
Its finally looking like a camper now. The last couple times it was hard for me to see anything being done to it since most of it was just painting and making cabinets. But this past weekend really paid off! We installed the closet, kitchen, cabinet over the kitchen and started the front wall. I also worked on the tongue jack hole again BUT I burnt out my 2nd dremel now. I have to check the bushings and dig into that. That blows. Here are some pics.
The closet in:
the wheel well thats going to be covered with the floor in the closet. (I made those wheel wells out of galv. duct sheeting).
The kitchen area. There is a wall that gets put up inside the cabinet area.
We put the Formica on. It was the first time ever doing that. The glue is fun to play with but don't think you'll pull it back off. We (she) picked a nice formica. Its look pretty close to the 60's. We also covered the table & backsplash with this too.
Then we installed the cabinet over the kitchen. And made the backsplash with some of the 1/4" ply and formica. You can see the "ice box" & the draw in the kitchen. The draw needs a face yet and I brought the ice box home to get the cleaning & buffing to freshen it up a little.
Since those were all in the next step was the front wall. We need the front wall in so we can place the table & benches. The only thing that was on the front wall from the factory was the window frame. It is hard to explain how it was. But we modified that alittle to make it stiffer. We framed in the whole front wall from the floor up to above the window. We measured the sheet metal from the bottom to the bottom of the window. This way we know where to place the window frame and know that we don't have to cut the alum. siding. We (Austin) had to make 4 legs that curved with the curve of the front wall.
Then we tried to apply the 1/4" ply to the inside of the front wall. I NEVER thought curving 1/4" ply would be that hard. We clamped and pushed, pulled & hammered and my fat ass barely got it in place! I would have never thought!!! You learn something everyday. But I'll be damn we got it! I hope it stays thought. We glued & screwed it. We're leaving it like this for 2 weeks (til I get back up there, have to go to a VW show next week in CT). Once I get back there the wall has to come out in one piece to be primered, painted & the molding put between the walls. Thats going to be a bitch!
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June 29th, 2009, 04:39 AM
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#16
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
I had another work weekend. Not to much to report. It was really just another painting weekend. We did make the cabinet that goes over the front table & benches. I took the front wall out and painted that and put the molding on it. My wife & I put it back in after the paint was dry. I painted the ceiling sheets (I have to do one more sheet, I miscounted). We installed the the the cabinet and stiffened the front wall up. We (Austin) made the drawer front and a cabinet door for the kitch area. Freshened up the slider part of the rear couch/bed. That was really it for the weekend. Austin had a cruise to go to Sat. and I was at a fair type of thing up there (Snake Hunt, long story if you don't know what that is).
Next weekend (July 4th weekend) is going to be another painting weekend, hopefully the last painting weekend since I'm getting tired of that.
We did start looking at the wiring layout. I got all the plumbing stuff. So now it starting the wirng and the gas line layout.
I do have a couple of pic of the front cabinet & the painted wall but the camera is at home. I'll save the pics for next weekend. We are getting closer.
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July 6th, 2009, 05:19 AM
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#17
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
Another slow weekend. It was the July 4th. I worked a little but my helper was getting ready for his clubs car show all weekend. I managed to get some stuff done.
Last weekends pic.
Front cabinet & wall painted and placed back in place:
This weekends pics.
I started to run the wiring for the trailer lights. I have in mind how and where to run them. The original ground was run to the alum. siding and the lights were ground to that. But everyone usually has problems down the road with the lights. I figure if you run a ground to each light that problem will be solved. What it one extra wire? If your going to do it just do it right.
I cut the front window out of the inside ply:
It was another painting weekend. Not as bad as before but I'm really getting tired of painting! Theres going to be another paint day but its going to be touchups and finishing. We'll save that for later. But I painted the slider part for the bed, the drawer face, & the cabinet door. Plus the piece I miscounted for the ceiling.
One this I'm very happy about is the tongue jack. Its finally in!! Its not bolted down yet but the hole is big enough to get the jack down in now! It just cost a new dremel and several grinding wheels for the drill. I burnt a dremel out working on the hole, then I rebuilt/fixed it, & burnt it out again. I'll have to see if its fixable this time. But who cares. The jacks in!!
We need another good weekend and the ceiling is going to be on. I'm trying to figure out when that is going to happen. It looks like the next 2 weekends aren't going to happen though.
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July 27th, 2009, 04:12 AM
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#18
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
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July 31st, 2009, 04:55 PM
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#19
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
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Re: Fleetwing Camper Build
OK since it the last day of July (CBOM). I figured I'd post a little update. I have been working on the camper for the last 3 days pretty good. We are getting it to the final stage and ready for prep for paint by the end of Sunday. There will be another update for the weekend.
I just want to say once again, getting Crazy Bastard of the Month is an honor. Thanks again!
Any how here some pics and what we did.
We plumbed the water system. There is a 10gal. fresh water tank (all new hose & stuff). The tank is under the front bench.
Then we wired all the outlets and lights. They aren't all in yet but the wires are run. We got the box out of the parts Scottys in the field (score).
I finished insulating the outside walls and trimmed for the wires. Then we started to Tyvek (house wrap) the sides. The front needs a piece of the ply yet (waiting on a brace/support to dry). Then the top insulation, Tyvek, and aluminum siding can be placed on the camper.
We did run into one problem that scared us. The ceiling/roof ply wants to kick out where they butt up againist the each other in the back area. I did get some old panelling molding (H molding) and thats how we joined the plys together. But it still wanted to kick out. So we used 3/4" wide metal band and strapped the whole camper. We have 3 straps that run from the front to the back and 2 straps the run from the top to the bottom in the back. I torq. them down while Austin screwed them fast. Problem solved!
Theres more done then that but thats the main stuff for this post. More to come after the weekend.
Last edited by Scott76; August 3rd, 2009 at 03:42 AM.
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August 3rd, 2009, 04:04 AM
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#20
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
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August 17th, 2009, 03:46 AM
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#21
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
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August 24th, 2009, 03:54 AM
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#22
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
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August 31st, 2009, 04:29 AM
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#23
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
We didn't go up and work on the camper this weekend. But I have been very busy with life and trying to get the alum. trim finished. It took some time but I get the trim finished lastnight. Now I got to start the windows. Boy this polishing & sealing is mighty fun!!!
First I have to clean the it with a red 3M pad with comet & water to get the rust and caulking off (use a razor blade for the hard caulking). Once the trim is cleaned then I buffed it with the red polishing bar (hold on to the piece it will twist and wear leather gloves because it DOES get very hot). Then use the Zoop metal polish. Then clean it with the Zoop cleaner. Then apply the Zoop seal (let it dry pretty good in the sun). Then apply the Zoop final sealer (final polish to buff the seal to a shine). It is very long and hard work. I would hate to see what it cost to have some one do it for you!! I'm hoping it last the 2 years they say it does. You can reapply the final sealer polish as many times as you wish. Any way its long hard work but it needs done! Heres some pics.
This is what I started with. You can see the rust and piting in the alum.:
Here is what it looks like now:
Here is what I used. This stuff is NOT cheap!! I odered it from Summit Racing. They were the cheapst that I could find shipped:
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October 19th, 2009, 06:34 PM
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#24
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
Well it been a long time since I had a chance to work on the camper. We had some free time this past weekend and got up to place the trim on it. It wasn't an easy task. I think it was the hardest so far. Because it has to cover gaps and corners and thats might not fit perfect. It was close, but we got it to work the best we can. I'm happy with it. I want to get it out of Austin's garage for the winter. So we have to make it all weather proof. The windows aren't polished but I have to spread the polishing fun out a little. I don't want to have all the fun at once. Well less talk more pics.
The orig. vent was just a mushroom cap vent. I went with a 14x14 vent. Yea thats right. I cut a hole in a perfect roof.
We plan to go back up in 2 weeks to get all the lights on and really weather prrof it solid.
All i realy have to say is that the trim really pops the camper now. It looks just unreal!!! I love it.
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August 1st, 2011, 04:51 AM
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#25
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Forum Member
Join Date: Mar 2007
Location: Fleetwood, PA
Posts: 3,964
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Re: Fleetwing Camper Build
Its been almost 2 years since we last did anything to the camper. We moved and had other stuff going on in the meantime. So it was stored away in safe keeping til now. We really want to go camping so the camper is pulled out to finish it. It was been in a nice new garage for the winter so it hasn't seen snow yet.
We finally had the cushions made at a upholstery shop with our fabric. I haven't cut the foam yet. Maybe this week. Laura is going to her gram's this coming weekend to help with the curtains with our fabric along with some pillows too. I know I haven't posted the fabric up but we had it since we painted the interior. Just keep in mind that we wanted to to a 60's-70's retro feel to the camper. So the fabric was picked for that reason.
The cushions fabric:
The fabric had other patterns in the color series so we picked the stripes for the curtains and the crazy pattern & dots for pillows.
The last things I had to do to finish the outside was to buff & polish the windows. I really didn't want to do it but it had to be done. I'm so tired of buffing & polishing alum. that I just want it over with. So I just did it over the weekend. I started Friday morning at 5am and I got done polishing Sunday afternoon. What a pain in the ass. But its done! I started out buffing the window as 1 piece but I knew that was a stupid move. So I sat down and studied the window. I had to drill out 4 rivits and the glass came out and 1 screw per corner and the frame came apart. So now I feel safer to buff the pieces.
Here is what I started with:
Buffed to this:
What the window looked like before I took it apart:
What the pieces look like drying in the sun after they were sealed.
While I was sealing the windows, Laura was painting the original window inside wood trim. She painted them the white to match the ceiling. I got new alum. screen to staple to the back before installing them back in the camper.
I started working inside now. I got the electric fuse box wired to the plug. I have 1 light to install above the table but I have to wait to see how far out the curtains stick out before I mount the light. Plus I have 2 Scotty lights that are going to be mounted to each side of the cabinet above the sink. Had to cut off a couple of long bolt that extend through the back wall that hold the tail lights on and painted over them. The sink need a little patch in the enamel and that is ready to be installed too. I have to get all the supplies I have for it out of storage yet. So stay tuned because this should be fast moving to get this on the road before the fall.
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