230 Photos - Feb 17, 2009
Photo: Day of delivery to my shopPhoto: Photo: Photo: Photo: Photo: Interior of the trailer as I received itPhoto: Photo: Starting to remove the interior panelsPhoto: most of the panels removedPhoto: pulling all of the insulation and electrical wiringPhoto: the interior after scrubbing and vacuuming the wallsPhoto: Photo: Photo: damage to repairPhoto: at some point in time, someone rammed the trailer with a fork liftPhoto: removal of the battery boxesPhoto: where the water heater wasPhoto: roof after all of the vent pipe jacks and everything else was removedPhoto: exterior stripped of all it's trimPhoto: hole where the refrigerator vent wasPhoto: site of old TV antennaPhoto: stove vent holePhoto: vent holePhoto: vent holesPhoto: Photo: stripping of the vinyl decalPhoto: Photo: Photo: The trailer is now ready for me to start stripping all of the clear coat finish from the skinPhoto: The holes where the old battery boxes were have had patches made and held in place with aircraft cleco fastenersPhoto: Patching the old stove vent holePhoto: Patching the bathroom vent holesPhoto: Patching the hole where the old water heater wasPhoto: After the patches have been riveted on placePhoto: Finished patches on battery box holesPhoto: Photo: Finished patch on stove ventPhoto: Finished parches on bathroom ventsPhoto: This long patch on the water heater opening will wrap down and under the trailer to cover a large dent in the bottom roll.Photo: Finished viewPhoto: CloseupPhoto: Before installing new openingPhoto: I have used on the old battery box doors to gain access to the inside of the trailer where I will house in a shallow box the hot water, cold water and propane quick connects outlets as well as the drain pipe for the exterior kitchen area.Photo: Future kitchenette service panelPhoto: Large dent on drivers side bottom roll before repair. There was a funky patch on it but I had to replace, no funky stuff!Photo: Old refrigerator vent hole after patchedPhoto: After the clear coat was stripped from the trailer.Photo: The source of the stench in the trailer. This is a bottom view of the floor panel that I cut out in the old bathroom area.Photo: The 4' x 5' area of the floor that was removedPhoto: The old black water tank (toilet) was removedPhoto: After the tank was removed and the area was cleaned.Photo: After the area was insulated and a new patch was installed. Only the gray water inlets remain, the exterior sink will drain into here. The entire floor was sprayed with several coats of a heavy bleach solution and the smell in now finally gone from the trailer.Photo: Removing the clear coat finish from the trailer.Photo: The trailer after all of the patches have been installed and the clear coat removed.Photo: The clean view of the rear of the trailer. Bumper removed, trunk pan cut out and removed, clear coat removed. All new running light wires hanging from the light housings.Photo: The trunk area before removing the old panPhoto: left side of the old broken bumperPhoto: Right side of the old bumperPhoto: A clean palette to work with.Photo: Even the door skin was removed so that the old insulation could be removed. It will be shot with the spray foam insulation.Photo: Everything has been cleaned.Photo: Interior skin panels being cleaned and made ready to re-install after wiring and insulation.Photo: The trailer will no longer smell!Photo: After all of the new wiring has been pulledPhoto: The strips that you see on the front and rear nose cones were added as backing strips for the future aluminum panels that will be added. The original plastic one piece panels will not be re-used, instead a Banana Wrap will be created using new aluminum.Photo: 4 gauge marine grade cables run through the roof to carry the power from the solar panels to the batteriesPhoto: 6 gauge wires were run to the 4 corners of the trailer to carry the power from incoming wind turbines.Photo: All of the wiring runs to just above the left side wheel well. The yellow is 7-110v lines, the multi colored is 12-12v lines, the red and black is the solar and wind charge lines and the blue is 13 Cat5E lines.Photo: everything is tight and cleanPhoto: Right side above cabinetPhoto: Finished wiringPhoto: left side at the power housePhoto: everything has bee coveredPhoto: All of the wiring had to be securely tied down to the trailer to prevent it from lifting when the spray foam is sprayed on. over 650 zip tie anchors and 1000 zip ties were used.Photo: George the Icynene spray foam expert getting ready to do his thingPhoto: once sprayed, the foam expands about 50 times it's laid on thicknessPhoto: Once the foam has dried in about 10 seconds, the excess is cut away to leave it flush with the frames.Photo: expanding foamPhoto: sprayed on about 1/4" thick the foam will rise to about 6-8" in 3 secondsPhoto: freshly sprayedPhoto: even though the wires were secure to the aluminum skin, sometimes they would want to pull away when the foam got behind them and a helping hand was needed to keep them in placePhoto: beginning to saw off the excess foamPhoto: The installers would skip around so that they could have access saw off the excessPhoto: The rear of the trailerPhoto: Here you can see how they would skip around and finish every other space before filling all of the spaces.Photo: The nose conePhoto: sawing off the excessPhoto: more sawingPhoto: skipping aroundPhoto: carving up the frontPhoto: They would use a long saw blade about the size of a yard stick.Photo: Closing inPhoto: exposed wire tales through the foamPhoto: Taking a break in their truckPhoto: getting close to being finishedPhoto: filling in the voids and gapsPhoto: doing the final carvingPhoto: Even the door was taken apart and sprayed with foamPhoto: The finished product!Photo: The trailer now has the perfect insulation with no voidsPhoto: All finished and ready for cleanup and the panels to be re-installedPhoto: As you may remember the front and rear nose cones were made of a single formed piece of molded fiberglass that was dried up and cracked and served no purpose in the future of the trailer. With careful calculations and some aluminum strips I was able to form what is referred to as a "Banana Wrap" to cover the inside curves.Photo: The finished surface gives the interior a much sleeker look and makes more room for the projector shelf.Photo: The left side was installed first then the right side was matched.Photo: Bad picture of the finished nose cone.Photo: Finished tail cone and lower panels installedPhoto: No upper cabinets in the way of a projector screen.Photo: After all of the original skins were re-installed I was left with several holes to deal with from the trailers original layout.Photo: Almost finished with the skins.Photo: Photo: Forward view after all panels have been installed and the trailer was cleaned up.Photo: Aft view of the same.Photo: All old holes have been patched and the surface is now ready for the Zolatone paint.Photo: Although all of the cigarette, urine and cat smells have been removed and the bad areas of the floor were cutout and patched, the floor is still in no condition to cover with flooring.Photo: Nice and clean!Photo: Clean lines.Photo: Ready for the new subfloorPhoto: The entire floor has been covered with 1/4" tempered Masonite to smooth out all of the uneven areas and patches.Photo: Once glued down, The Masonite will float over small imperfections in the surface.Photo: Here you can see how rough the old floor is.Photo: Lots of glue was used to bed the Masonite to the old surface.Photo: You can never use to much glue.Photo: A smooth clean surface that is now ready for the Marmoleum flooring to be installed.Photo: We now have a clean shell to work with. All of the work that has been completed to date is the work that no one will ever see!It took several months just to get back to and empty trailer that is now ready to finish out.Photo: All labor to this point! Now is when the fun begins.Photo: A clean open palette to work with.Photo: Now we start on building the interior.Photo: template for the rear cabinetPhoto: contoured edgesPhoto: opening in floor for generatorPhoto: Photo: making the template for the front shelfPhoto: not an easy processPhoto: The building of the cabinet basesPhoto: curved ends for benches and sofaPhoto: detail of woodworkPhoto: Photo: beginning of the sofa seating basePhoto: cabinets and refrigerator installedPhoto: painted Zolatone interior with center line lights installedPhoto: center ceiling lightsPhoto: installed generator with access door openingPhoto: cut out in floor and dropped to be flush with the bottom of trailer framePhoto: a welded steel support frame carries the weightPhoto: detail of curved sofa framePhoto: sofa frame basePhoto: sofa framePhoto: lighting system panel by the front door. rivets will be painted out. 4 - 12 volt dimmers for the 4 lighting zones and switches for the exterior lightsPhoto: updated original speakersPhoto: shelf over front window to carry projectorPhoto: looking forwardPhoto: detail of Marmoleum floor and cabinet base with weltingPhoto: Farmlab green exterior color next to Marmoleum floor color and woodworkPhoto: closeup of floor, reminds me of Alfalfa!Photo: through the doorPhoto: exterior boxPhoto: cleaned and polished rimsPhoto: all painted areas have been sanded for paintPhoto: installed refrigerator through access door openingPhoto: new vent for refrigerator will be painted outPhoto: sanded tongue with welded plate on forklift holePhoto: VGA, 110, CAT5e and 12 volt over front shelf for porjectorPhoto: dimmers and light switchesPhoto: mid cabinets looking aftPhoto: The wall lights on in the mail and are the only exposed wiring left to doPhoto: detail of cornerPhoto: sofa cornerPhoto: right sidePhoto: under counter 110-propane refrigeratorPhoto: Photo: installing the weltingPhoto: Photo: left sidePhoto: dinette benchesPhoto: detailPhoto: rear cabinetPhoto: CAT5e, 110 and cable on rear cabinetPhoto: open hatch door on top of rear hatch with projector screen mounted insidePhoto: retractable projector screenPhoto: forced air propane heater awaiting ductingPhoto: looking forwardPhoto: 12 solar panels on the roofPhoto: Photo:                                Photo:                                Photo: Photo:                                Photo: Photo:                                Photo: Photo:                                Photo:                                Photo: Photo: Photo: Photo: Photo: Another Airstream renovation by Craig DorseyPhoto: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Complete knowledge of inverted power is just one of my skill sets.Photo: Photo: Photo:                                Photo: Photo: Photo: Photo: Photo:                                Photo: Photo: Photo: Photo: Photo: Photo:                                Photo: Photo: Photo: Photo: Photo:                                Photo: