Cabover rebuild project

Sportsdad · Sep 14, 2009

I was inspired by Memory Roads, knowing that the previous owner had issues with the window up front, and the edge separation from the side panel to the cabover floor meant I was about to start a bigger project than anticipated!

THANKFULL, Memoryroads has been on this journey, and I'll be using his blog extensively for my rebuild.
http://memoryroads.blogspot.com/

I know my job won't turn out as exceptional as his since I haven't worked with wood for years, but I'm into it now, no backing out.

I intend to do this in 3 stages:
--upper rebuild of cabover tieing into solid upper wood and cover window.
--frontal rebuild and flooring
--Sealing it up, final paint.

(Interior will be a 'spring' job next year.

As I began to explore, it didn't look pretty... musty smell starting filling my nostrils as I exlored deeper. Final verdict: partial Cabover rebuild with intentions to remove the window.

After pics below. I spent about 6 hours tearing it apart, keeping the old wood in tack to the best of my ability, for later measurements.

Next step is "clean up" on the steel frame, including rustoleum finish.

Tear off complete

Extensive rotting on the main floor and bracing of cabover

The large 6 ft window caused most of this water damage

Upper wood structure yet to be removed, measured for dimension. Steel frame yet to be cleaned up.

Sportsdad · Sep 14, 2009

Alittle history on this MH. We bought it from a 2nd owner in Aug 2008 and used the HECK out of it in the last year. Always garaged. Its' in good shape, only 42,000 miles on it. Interior was mint, except for the carpet.(wear and tear) I replaced the carpet in the back bedroom with vinyl tile (you can see a pic of it in the album)
Here are some pics of it before I started tearing into it.
http://www.picturetrail.com/sfx/album/view/21767624

Sportsdad · Sep 22, 2009

I finished cutting most of the pieces for the frame on the front of the cabover. (No picture yet, will take one when I bolt it in place)
Here is a pic of the completed leading edge where the fiberglass shell will wrap around and under the cabover, side by side with the old structure:

http://pic100.picturetrail.com/VOL767/2726312/21802801/374420729.jpg
[edit]Fixed link.[/edit]

PancakeBill · Sep 23, 2009

Those front windows! Same with slide-in campers, major source of leaks, both moisture and thermal. On my Coachmen I covered and insulated the front windows. If I had to do anything major I would have eliminated them. Funny thing, the new owner is re-glassing the windows, he will learn.

Good luck with a major undertaking.

mayfair · Sep 23, 2009

HOLY CRAP that is one HELUVA job !!

Good luck !!

Sportsdad · Sep 25, 2009

Finished removing the rest of the rotten wood going up the frame and then finished some new framing, temporarily installed the leading edge, and added plywood to inner portion of the camper today.

Sportsdad · Sep 27, 2009

Today I sealed those cross beams beneath the outter skin of plywood and sealed the plywood itself, with West epoxy system.

Cleaned up the upper filon and fiberglass taped the edges that were beat up. Mathced, traced and cut out the interior finish piece that will be glued to the bottom board on the top side.

Cleaned up the .100 thick filon leading cap that goes over the leading curved edge. Lots of elbow grease and ketone.

8 hours of work, but not much to show for it, just small details today. I'm in hold until the new filon (8 ft. by 8ft piece) arrives, which may be 2 weeks.

In the meantime, I'll sand the upper existing filon to prep for Awlgrip paint, as well as adhering it back down to the surface.

I didn't think I'd be this far ahead so soon. So far I'm into it for $562.00 and about 34 hours of work.

PIC:
West coast epoxy sealed front frame and outer plywood skin (which the filon will attach to:

PancakeBill · Sep 27, 2009

Will you be doing the underside and wrap with that one piece?

Sportsdad · Sep 27, 2009

PancakeBill said:
Will you be doing the underside and wrap with that one piece?

I Can't wrap it in one piece, due to the bed being 6' wide, it requires two plywood floor boards. It's easier to show you pics than try to explain it.

loaneylonely · Oct 3, 2009

Sure do have a lot of things to fix up post some photos
if your work is finish pretty excited to see it.

Sportsdad · Oct 5, 2009

I'm currently in limbo. My buddy can't fabricate the filon pieces I ordered until at least Oct. 13th. I expect to have them later in the month, but in the meantime, I'm just doing what I can while waiting for the pieces of filon.

I added some insulation to the leading edge nose (pic 1) and then attached the outter skin panel (The entire front has West Epoxy coating, no future water damage here!).

Then I added 1.5" insulfoam type 2 in the interior of the cabover, (pic 2) and then sealed it up with the interior panel (pic 3).

This creates a very strong "sandwich", two pieces of 1/4" plywood (total 1/2" thick) and foam core (Pic 4). The kids should be nice and toasty on those cold winter nights at ski camp.

I also spent time adding Eternabond tape to the seams of the roof (for those of you RV'ers, you know how great this stuff is!) to ensure I won't have to do a roof rebuild in the future!

http://pic100.picturetrail.com/VOL767/2726312/22555210/375310784.jpg

http://pic100.picturetrail.com/VOL767/2726312/22555210/375468008.jpg

http://pic100.picturetrail.com/VOL767/2726312/22555210/375468009.jpg

http://pic100.picturetrail.com/VOL767/2726312/22555210/375468005.jpg

Sportsdad · Oct 16, 2009

The Filon arrived today.

The first piece of filon was cemented in place on the first bedboard, then installed. Both 1st and 2nd 'extention' piece of filon-backed 3/4" was then attached with self-tapping Machine screws into the metal frame on the sidewalls. I have it propped up in place to prevent the slight sag between the two pieces of 3/4". I will fiberglass tape these two sections from the inside.

The next step is attaching the outter piece of filon that wraps around the nose, which will cover the 2nd piece of 3/4" plywood.

http://pic100.picturetrail.com/VOL767/2726312/22555210/376166325.jpg

http://pic100.picturetrail.com/VOL767/2726312/22555210/376166330.jpg

http://pic100.picturetrail.com/VOL767/2726312/22555210/376166327.jpg

mayfair · Oct 19, 2009

Sportsdad said:
I also spent time adding Eternabond tape to the seams of the roof (for those of you RV'ers, you know how great this stuff is!) to ensure I won't have to do a roof rebuild in the future!

I just used Eternabond. That stuff is AWESOME !!

Sportsdad · Oct 19, 2009

I finished the interior yesterday (minus the molding) with a white oak finish panel and all I have left now is to put the final piece of fiberglass around the cabover, plan on doing it this Sunday. I am 2 months ahead of schedule on this project, thanks to an understanding wife! I have about 55 hours into it now.

Interior complete except for molding, trim on the edges of the paneling:
http://pic100.picturetrail.com/VOL767/2726312/22555210/376344586.jpg

Top portion of fiberglass filon was salvaged, sanded, primered and painted with Interlux exterior boat paint. Final new piece of fiberglass filon yet to be added as well as exterior molding/trim:
http://pic100.picturetrail.com/VOL767/2726312/22555210/376344585.jpg

Tom · Oct 19, 2009

Sportsdad, I've been following your posts and your photos. You're doing a really nice job! Thanks for sharing.

Sportsdad · Oct 19, 2009

Thanks Tom. Appreciate the kudos!

Sportsdad · Oct 26, 2009

Progress has slowed due to a cold front and rain. (Contact cement and cold, humid weather don't mix well)

My dad is in town this week, yesterday we got a break in the weather in early afternoon, humidity was about 65% and temp was about 55 deg, so we decided to apply the upper part of the filon first. We'll let this cure for a few days and attempt to complete the wrap around later in the week as the rain and cold weather is back with us.

The "bubbles" you see on the seam is the plastic protective film that peels off once we're done. I'm going to caulk some 3M 5200 sealant in the small seam, and use an aluminum strip with butyl tape to cover the seam.

Duct tape is temporary to hold everything down as the contact cement sets up.

Final Filon

PatrioticStabilist · Oct 26, 2009

I've been working in the cabover of ours. How in the world did you get that up there in the cab? I'm just working on a window and some curtains and its miserable. I can't even imagine trying to put that up, fasten it and everything. You have my admiration, as I know you have worked really hard on that. I hope we never have to do it.

Sportsdad · Oct 26, 2009

Thank you, and I've been following your thread as well. The admiration works both ways!

I've been using a rather unsafe "plank and ladders" method, but if you feel safer, you can build a temporary scaffolding like memoryroads did here:

Temp Scaffolding

PatrioticStabilist · Oct 26, 2009

When my Eternabond comes in I have got to get the top done. Hubby has those big heavy folding ladders. He said take 2 of those, 1 on each side a make a scaffold. I will get my tenant to lift them, those things are beyond heavy.

That's a nice scaffold he built, would do the job that's for sure.

Cabover rebuild project

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