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.

Love and Marriage! Putting Shell & Chassis Back Together

Like the old song - 
Love and Marriage, Love & Marriage - Goes together like a horse and carriage...
Shell & Chassis, Shell & Chassis - Goes together!!

Aluminum Haircut

The belly pan aluminum is trimmed to be flush with the top of the C-Channel.

Floor Attached to Frame!

Construction!
No longer pulling things apart!
All the preparation work is complete, things are going back together again, and I could not be any happier!!

The old leaf spring axle is gone, white the new smoother riding torsion axle is positioned and the bracket is attached to the frame.

Glue is used to attach the plywood floor is to the frame.

Elevator bolts are used by the Airstream factory to attach the C-Channel to the outriggers only - so they are spaced widely apart, approximately every 2 feet.  Then the factory used (uses) self taping screws are used to attach the C-Channel to the plywood between the outriggers.  
Our 1955 Flying Cloud has Colin's added strength by using elevator bolts inside the C-channel - all along the C-Channel to more securely attach the frame to the floor and therefore lessen stress to the trailer.  The elevator bolts are attached to the outriggers and to the plywood floor.  Colin used self-taping screws to further secure the plywood floor to the outriggers and the cross members.
Improved again!  Even the curves are attached with elevator bolts - every 8" to 10".

Using the rotisserie, our Airstream is moved to comfortable positions for securely bolting the floor and chassis together. Shown with the hold-down plate welded to the front of the frame.  The extra elevator bolts are best seen in the photo from the under-side of the plywood floor.

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.

Peeping Tom

Peeping into our walls - this is our first look - photos sent by Colin from Plattsburgh NY.


We expected water damage in the toilet room. And under the front jalousie window / water tank.

And as always the back floor. I need to ask Colin why the metal at the base is not one solid piece...
 
As usual my question has been asked and answered on the Vintage Airstream Podcast (VAP) 
I'll try to find the episode number, I think it is somewhere in the 190's....  
My understanding is that the early years Airstreams were made with the C-Channels installed in pieces.  Colin let me know that we would improving the trailer with a more water resistant solid C-Channel is is done for modern Airstream trailers.


More photos at Byam's 1955 Flying Cloud.