Improvement to Original Shell Structure - Wheel Well Support

Airstreams are built to last.  Part of the durability is how the shell is attached with rivets to C-Channels which are bolted to the floor and frame.

Back in 1955, two areas where the interior aluminum walls were not secured to the wall structure are the wheel wells.  Colin was careful to improve our trailer during restoration.  C-Channels were added to the wheel well - to secure this area of potential weakness.

Sorry for the fuzziness of this second photo.

Almost Mobile - Axle Mounted

For softer travel and longevity of our vintage Airstream, we changed from the original leaf spring axles to torsion axles.

The center belly pan is prepared and positioned for rivets.

The new torsion axles are mounted.

 The axles are bolted onto the mounting plates, and the brakes are wired.

Trailer shocks were installed, attached to the shock mounts in the wheel well.  This photo shows the street-side wheel well that was reshaped with an adjusted offset for room for the toilet.

Wheel Well

While working on the insulation, the wheel wells were sealed in preparation for undercoating.

 










The upper mount for the shock absorbers were installed. 
Many trailers don't have shocks, perhaps because for most trailers have limited life expectancy.  Airstream trailers are a delightful exception to the planned obsolescence.  Most Airstreams will be on the road for decades!

The wheel wells were undercoated using an automotive undercoating to protect the metal.

Position the Plumbing and Narrow the Wheel Well

I need a shower and we also want to keep the living space as open as possible so we need to crowd the bathroom.  Before when we checked the fit, there is very little room between the toilet and the wheel wheel. 

 As new plywood is cut for a floor, the size and shape of the trailer can tweak a little bit.  Now our 1955 Flying Cloud final size of the Airstream is defined by the floor attached to the chassis.  With the wheel wells attached between the plywood and the frame, the bathroom plumbing needed to be double checked. 

Axle and tires on, the chassis is flipped over.

Great news!  The shell still fits on the floor/frame!

Next the plumbing parts are laid out in their approximate positions.

The mock-up wall is brought back into our trailer to check the fit.

With the new axle and tire in place, we could check that all would still fit, and as expected the wheel well needed to be slightly adjusted.

Floor to Frame - Details

Aluminum was used to protect the plywood floor at the spare tire.

Aluminum protecting the floor above the step.

The inside of the wheel well.

Location, Position, Check, and Double Check

I'm so excited!  We are getting closer to putting the aluminum shell back onto the frame!

Wheel well is located close to the shower pan.  Both locations are finalized and the shower pan is checked to fit and be supported by the cross members. 

To keep water from damaging our new floor, the plywood is sealed or waterproofed.  Colin uses Smiths CPES Penetrating Epoxy 2 part epoxy.  The underside is soaked and the upper side is sealed at the outer edges of each board.

 













The C-Channel will hold the wall and provides the stability and contact between the wall and the wood floor and chassis below. 

The curved C-Channel for the front and rear corners was made in 1955 by Airstream in small segments. Colin fabricated new C-Channels from 032 aka 50/50 aluminum "belly pan" aluminum.
Then the C-Channel is positioned on the floor, checking the fit again.

All is Well!

The bottom flange of the wheel well was rusted and needed replacement.

The balance of the wheel well is in good shape. 
We are fortunate to have a vintage Airstream with metal wheel wells.  Changed sometime in the 1970's, some later model trailers have wheel wells instead made with a thermoform plastic.  Some of the thermoform plastic wheel wells have over time cracked or degraded.

New galvanized steel was used to form the flange.

Positioned on the trailer for size.

Clamped and attached. 

Our new wheel wells are positioned on the frame, ready to be sealed with Vulkem, caulk, and then painted.  The hold-down plate is ready for the C-Channel, and then the shell!

We own a new toilet!! Good Bye Gopher Hole!

Some things vintage are worth keeping and restoring.  Other things, while historical are not worth keeping.  Well, the old toilet had to be replaced - our new toilet arrived and it fits. Good bye gopher hole! Hello black tank! The black tank (to hold toilet contents) will be located under the new toilet.  The decision is made - above the floor and under the toilet as shown by the mock-up box right next to the wheel well.  Approximately 13 gallons is the plan.