Off of the Grid

Posts tagged “aluminum

Aluminum is Down! (This means we have a floor)

The generator has been serviced, all the spot welding has been done. It was time to finally lay down the first level of the floor structure. We found some great aluminum at a trailer truck shop. It’s thicker than what was there before and more affordable. We got enough to do the entire floor and the cab-over. It is wider than the chassis so we are folding up the excess to give the base layers more stability and offer some additional protection from water. 1/4″ plywood is the first layer of wood. Next comes the insulation, 3/4″ plywood and our floor. At this point, I am fairly sure that we are just going to put in a wood floor and poly it. We will see as time progresses though.

I am going to stop talking and just post the pics.Β  Here ya go.

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Teardown Complete!

YAY! We finally got the last of the old flooring out. Now there is just the frame and the chassis of the trailer. We have some wood cobbled together in-case we need to make the RV street safe but that is off to the side.

WOW! Just had to get that off my chest. OK. Here is what we found.

  • We found both steel beams bent by the passenger side rear dullies. Not sure what would have caused this kind of damage in this spot. Massive over burden? Improperly placed jacks? Accident? These will need to be removed and replaced.
  • Rust – a bunch of rust but fortunately less than we were expecting. You can tell this rig was not an East Coast vehicle. I was terrified we would get everything off only to discover that road salt had eaten away the very base of our home. At that point, we would be game over and homeless. There is a reason I haven’t been sleeping very well at night. The rust that we did find is treatable. PHEW!
  • The back steel beam going across the rear of the RV is slightly bowed up. You can see from the pictures. Again, not sure what would have caused this damage. We know from the people we bought the RV from there was extensive back end damage from them backing into something. I can’t remember what. This damage could have been caused by that. It looks like something we can hammer back into place but I will defer that to the hubby and a body shop.
  • We still have that one steel beam that is broken off the ‘C’ bracket extension. I showed that image previously but will edit the photo to make it a bit more obvious.

Otherwise, things look good! Everything from this point forward is a step towards putting Winnie back together. Stronger, and Better than before. When we are done, we will have a custom brand new 2017 RV. Β πŸ™‚


Ripping Off the Roof…

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 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. Β 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.

 


Deconstruction almost complete

We have the walls completely off. We disassembled the cab-over yesterday and got all the rotted wood out and exposed the frame. Now we are working on the roof. Yesterday Daniel spent time on the ladder trying to get the roof off from the center out. Sounds weird until you remember that we had a piece of filon tacked up there to patch a leak. So, instead of trying to pull the roof off from one of the sides, we just went to the place in the center where we had already ripped and cut the worst parts of the damage out. Daniel just pulled off that filon strip and got to work on the rest of the roof. Xander and I spent some time picking up the small pieces of insulation off the ground. Our friends are being so incredibly awesome to let us work here, I am certainly not going to pollute their property! We have enough debris for another dump run so we will get that done today or tomorrow. Then we will remove the floor, and check the aluminum sheet on the bottom of the bed and replace the wood that we see that is rotted down there. Bit worried we will have to replace that sheet since aluminum is pricey!

You have to keep a sense of humor in all this, so Daniel has been having some fun with Gimp and editing our progress photos. Check ’em out!

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Here are in-progress photos of the rig, the frame and where are at with this project.

Here are our ‘To-Do’ tasks for the day:

  1. Go talk to more service shops about the frame and our ideas. We don’t think we will need to do any additional extending to the frame with out 3′ addition based on our discovery of the ‘C’ bracket extension already there but we want to ask as many shops as we can before building.
  2. Start calling welding shops and metal supply shops
  3. Do the drafting to get the placement of the changes to the frame we need, and finalize the floor plan with the measurements.
  4. Get to dump (maybe – if we have time)
  5. Remove more of roof this evening and get that back section that is hanging removed.

There ya go! We will keep you posted. Would love to hear your comments – other than ‘You’re Crazy!’ – we already know that. LOL!