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Author Topic: Cabover rebuild project  (Read 17635 times)

Sportsdad

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Cabover rebuild project
« on: September 14, 2009, 08:28:59 AM »
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
(http://pic100.picturetrail.com/VOL767/2726312/21767624/374036752.jpg)

Extensive rotting on the main floor and bracing of cabover
(http://pic100.picturetrail.com/VOL767/2726312/21767624/374036753.jpg)

The large 6 ft window caused most of this water damage
(http://pic100.picturetrail.com/VOL767/2726312/21767624/374036755.jpg)

Upper wood structure yet to be removed, measured for dimension. Steel frame yet to be cleaned up.
(http://pic100.picturetrail.com/VOL767/2726312/21767624/374036749.jpg)

Sportsdad

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Re: Cabover rebuild project
« Reply #1 on: September 14, 2009, 11:10:12 AM »
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
« Last Edit: September 14, 2009, 11:19:20 AM by Sportsdad »

Sportsdad

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Re: Cabover rebuild project
« Reply #2 on: September 22, 2009, 05:04:44 PM »
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]

« Last Edit: September 22, 2009, 08:04:55 PM by Tom »

PancakeBill

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Re: Cabover rebuild project
« Reply #3 on: September 23, 2009, 09:52:33 AM »
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. 

Bill & Jolene W & Koda

Old Faithful, Yellowstone Association Bookstore
1997 Southwind 35P
Toads: 1997 Honda Accord & 1986 Westfalia
FMCA F-401354
1995 OMI Dobro F-60
WA1RI

mayfair

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Re: Cabover rebuild project
« Reply #4 on: September 23, 2009, 11:27:39 AM »
HOLY CRAP that is one HELUVA job !!

Good luck !!
1999 24' Prowler bunkhouse

towing with ...

1998.5 Dodge Ram 4X4 with a Cummins Turbo Diesel

Sportsdad

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Re: Cabover rebuild project
« Reply #5 on: September 25, 2009, 06:32:22 PM »
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.
(http://pic100.picturetrail.com/VOL767/2726312/22555210/374822483.jpg)

(http://pic100.picturetrail.com/VOL767/2726312/22555210/374822468.jpg)

Sportsdad

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Re: Cabover rebuild project
« Reply #6 on: September 27, 2009, 07:33:58 PM »
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:
(http://pic100.picturetrail.com/VOL767/2726312/22555210/374959428.jpg)

PancakeBill

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Re: Cabover rebuild project
« Reply #7 on: September 27, 2009, 09:06:36 PM »
Will you be doing the underside and wrap with that one piece? 
Bill & Jolene W & Koda

Old Faithful, Yellowstone Association Bookstore
1997 Southwind 35P
Toads: 1997 Honda Accord & 1986 Westfalia
FMCA F-401354
1995 OMI Dobro F-60
WA1RI

Sportsdad

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Re: Cabover rebuild project
« Reply #8 on: September 27, 2009, 09:59:01 PM »
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

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Re: Cabover rebuild project
« Reply #9 on: October 03, 2009, 07:42:32 AM »
Sure do have a lot of things to fix up post some photos
if your work is finish pretty excited to see it.

Sportsdad

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Re: Cabover rebuild project
« Reply #10 on: October 05, 2009, 02:03:56 PM »
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
« Last Edit: October 05, 2009, 06:29:28 PM by Sportsdad »

Sportsdad

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Re: Cabover rebuild project
« Reply #11 on: October 16, 2009, 05:30:24 PM »
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

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Re: Cabover rebuild project
« Reply #12 on: October 18, 2009, 11:56:56 PM »

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 !!
1999 24' Prowler bunkhouse

towing with ...

1998.5 Dodge Ram 4X4 with a Cummins Turbo Diesel

Sportsdad

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Re: Cabover rebuild project
« Reply #13 on: October 19, 2009, 10:39:41 AM »
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

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Re: Cabover rebuild project
« Reply #14 on: October 19, 2009, 11:25:10 AM »
Sportsdad, I've been following your posts and your photos. You're doing a really nice job! Thanks for sharing.
Tom.  Need help? Click the Help button in the toolbar above.

Sportsdad

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Re: Cabover rebuild project
« Reply #15 on: October 19, 2009, 12:48:28 PM »
Thanks Tom. Appreciate the kudos!


Sportsdad

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Re: Cabover rebuild project
« Reply #16 on: October 26, 2009, 08:04:48 AM »
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

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Re: Cabover rebuild project
« Reply #17 on: October 26, 2009, 09:39:30 AM »
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.
Added 1992 American Eagle diesel pusher 38 ft

Winnie Sightseer 29 ', 2005 Class A 2 slides!  Bought 5/5/2010, Sold 1/7/2012. Added Tru Center , Trac Bar,  Air bags, Bilstein shocks Compressor for air bags, new awnings . New tires. New satellite dome, 2 flat screens
SOLD 6/17-10 Ford Aluma Lite

Sportsdad

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Re: Cabover rebuild project
« Reply #18 on: October 26, 2009, 11:38:38 AM »
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

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Re: Cabover rebuild project
« Reply #19 on: October 26, 2009, 11:43:12 AM »
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.
Added 1992 American Eagle diesel pusher 38 ft

Winnie Sightseer 29 ', 2005 Class A 2 slides!  Bought 5/5/2010, Sold 1/7/2012. Added Tru Center , Trac Bar,  Air bags, Bilstein shocks Compressor for air bags, new awnings . New tires. New satellite dome, 2 flat screens
SOLD 6/17-10 Ford Aluma Lite

Sportsdad

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Re: Cabover rebuild project
« Reply #20 on: October 28, 2009, 06:13:52 PM »
We made the final bend around the leading edge today.

First picture shows the propane heater at the far end and ceramic heater nearest, that warmed up the .06 filon to make it easier to conform and reduce chances of cracking.

Second picture shows the 2X4s that held it underneath after sealing and screwing the edges (Stainless steel countersunk screws)

Third picture shows how we kept pressure on the leading edge. This was my dads idea and it worked great!

Just alittle sealing of the edges with 3M 5200 caulk and apply the eternabond tape to the edges, seams and were finished!
Hope to have a final picture this week-end. Depends how fast my double back eternabond tape ships.

Heating the filon to reduce stress

Bracing beneath filon

Leading edge bracing

PatrioticStabilist

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Re: Cabover rebuild project
« Reply #21 on: October 31, 2009, 08:53:55 PM »
That is a lot of work and its going to look great.

What happened to it that you had to do all that?
Added 1992 American Eagle diesel pusher 38 ft

Winnie Sightseer 29 ', 2005 Class A 2 slides!  Bought 5/5/2010, Sold 1/7/2012. Added Tru Center , Trac Bar,  Air bags, Bilstein shocks Compressor for air bags, new awnings . New tires. New satellite dome, 2 flat screens
SOLD 6/17-10 Ford Aluma Lite

Sportsdad

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Re: Cabover rebuild project
« Reply #22 on: November 01, 2009, 08:47:31 PM »
That is a lot of work and its going to look great.

What happened to it that you had to do all that?
When we bought the unit, I negotiated the price down from the private owner by $2000, due to some heavy caulking on the edge, knowing it had issues with the wood in the cabover. The mileage was low (42k) but I knew I had some work down the road.  After over a year of ownership, I decided to "dig into" the issue and my work was literally cut out for me.  :) Since we're doing a 2 week trip next year to Minn, I decided to take care of business now.

Sportsdad

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Re: Cabover rebuild project
« Reply #23 on: November 05, 2009, 07:22:54 AM »
FINISHED! Well, finished for this winter anyway. I'll be doing the exterior trim molding with fiberglass next spring. For now, the eternabond tape will get her through wet and snow. The arctic white doesn't match the cream color of the motor home, but what the hell, I'm a redneck at heart. :)

Finished for winter 1

Finished for winter 2

Trim piece that joins two pieces of filon, underneath cabover

Finished for winter 4

Interior

PatrioticStabilist

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Re: Cabover rebuild project
« Reply #24 on: November 05, 2009, 01:16:49 PM »
That looks awesome, will be better then new!
Added 1992 American Eagle diesel pusher 38 ft

Winnie Sightseer 29 ', 2005 Class A 2 slides!  Bought 5/5/2010, Sold 1/7/2012. Added Tru Center , Trac Bar,  Air bags, Bilstein shocks Compressor for air bags, new awnings . New tires. New satellite dome, 2 flat screens
SOLD 6/17-10 Ford Aluma Lite

PancakeBill

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Re: Cabover rebuild project
« Reply #25 on: November 08, 2009, 08:52:06 PM »
Great job, and project updates!

Bill & Jolene W & Koda

Old Faithful, Yellowstone Association Bookstore
1997 Southwind 35P
Toads: 1997 Honda Accord & 1986 Westfalia
FMCA F-401354
1995 OMI Dobro F-60
WA1RI

JNewkirk77

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Re: Cabover rebuild project
« Reply #26 on: November 08, 2009, 10:53:53 PM »
That looks awesome!  Hopefully if I ever have to do that to our Jayco, I can do half as well as you've done with this one!
2000 Jayco Designer 2730W
Ford E450 chassis (6.8L)
"Livin' large on a small scale!"

mayfair

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Re: Cabover rebuild project
« Reply #27 on: November 09, 2009, 04:29:40 PM »
You're a MADMAN !!

That looks AWESOME !!
1999 24' Prowler bunkhouse

towing with ...

1998.5 Dodge Ram 4X4 with a Cummins Turbo Diesel

jeverden

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  • 1999 FourWinds Windsport 30Q
Re: Cabover rebuild project
« Reply #28 on: November 14, 2009, 08:54:18 AM »
Is your trade autobody or did you work for an RV company?

I have a class A 99 Fourwinds Windsport 30Q with some slight de lamination at the very top front right side  - Any thoughts on best way to repair?
I was told to drill small holes through, then inject with autobody resin - Brace with a 2 x 4

Amazing Work!!




Sportsdad

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Re: Cabover rebuild project
« Reply #29 on: November 14, 2009, 09:12:22 AM »
Is your trade autobody or did you work for an RV company?

I have a class A 99 Fourwinds Windsport 30Q with some slight de lamination at the very top front right side  - Any thoughts on best way to repair?
I was told to drill small holes through, then inject with autobody resin - Brace with a 2 x 4

Amazing Work!!
LOL! No! I'm an IT project manager by day, and a pretend-wanna-be-body guy at night! Seriously, I just did it myself to save some bucks after getting quotes between $3000-$5000 to have the work done by an RV shop. Thanks for the ultimate compliment though! I probably overbuilt it more than I needed to, but that's how the company I work for builds its airplanes. :)

I'm not really qualified to give advice on your issue, but a photo of the problem area would certainly help.  If you live in the greater Seattle Tacoma area of WA state, you're more than welcome to bring it over and we can assess what needs to be done.
« Last Edit: November 14, 2009, 09:15:56 AM by Sportsdad »