We have progressed!
We ended up taking a day or two off just as a sanity break and also to try and find a welder who would come out and weld some additional aluminum supports that will support the changes we want to make. We have called people, talked to shops, shown pictures of our chassis and now feel confident that we are good to go! Our RV chassis was already extended – presumably by Ford when they make it. Apparently our model was designed to be a sporty model with the ability to tow. There are already big ‘C’ brackets in the back of the frame with diagonal steel beams that go up to the bed. These diagonal braces will support the house extension. We are going to add one more steel brace just because we are paranoid and this is our only home but we are told we don’t need to.
We are having some trouble finding a welder. If we can’t get the extensions to the aluminum frame welded, we will have to extend the aluminum frame using bolts and brackets. It will still provide the additional support/strength we want, it just won’t be as clean.
This is the current status of the RV. The aluminum frame has all been sanded and cleaned. We built a wooden cover for the cab so we can drive it safely.
We discovered that if we chisel a bit, we can clean the aluminum faster.
sanding, sanding and more sanding.
SCARY! Old, old, bad roof. SO glad we are replacing this and will have a nice new roof for our home.
This has been an interesting process. We have experience in general construction, and RV construction. We are paying extra attention to weight, the frame, the design, and the chassis. Every aspect of this rebuild is being closely examined. The conversation never stops about what we are learning/discovering/confirming. We are not taking this rebuild lightly. This is our home. And it will be our home for some time. We are doing what we are doing to ensure our home provides the stability we need for it to last for the next however many years. However, the comments we are getting from some people are incredibly offensive. One welder we called to weld the additional aluminum beams, actually said these words.
You have gone to far! You never should have exposed the frame like that!
He had no idea who we were, why we are doing what we are doing, what our experience level is – the only thing he had to go on way my initial 5 minute call and the two in-progress pictures I sent. “I am not taking on this project. No.” He says.
Another person on a forum we participate in, just posted:
“Holy crap, 3 foot extension!!! Make sure to come back and post pics of your RV when it breaks in half.”
WTF? Really people?
Obviously we are sharing this with the world wide web. Obviously we are going to get comments from people who are going to disagree with what we are doing. I get that. What I don’t understand is the rudeness. The absolute lack of any effort to either find out who we are and what we are capable of. To what purpose are such comments made?
Moving on – our next steps are to remove the floor. We want to get up close and in person on that chassis. We want to see everything top and bottom before we start rebuilding. We will be putting Winnie up on ramps so we can really get under there. Since our rig came from the midwest, we know there is a lot of salt road damage that we are expecting to find. We know that the aluminum sheet at the bottom of the floor on the chassis is full of pits. That will have to be replaced. So, lots more work to do. I will keep you posted.