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#365138 - 09/15/06 09:25 PM
Re: "Toybox" trailer project (7) "The final details"
[Re: Barry Wolk]
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Barry Wolk
Member
Registered: 06/17/03
Posts: 1146
Loc: Farmington Hills, MI
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9-15-2006 Back at it.
Stripped off the FRP from the damaged areas. Removed foam from wall cavaties. The foam stuck very well to exposed surfaces. did not stick to tar.
Found broken studs and bent door frame supports. Both simple parts to duplicate.
Once the bent supports were removed the door frame was simple to straighten but left some cosmetic scars.
A little hammer and dolly work.
Coarse through 600 grit sanding.
Some compounding. I think it looks fine.
I decided to replace the bottom 24" of Alclad in the damage area.
I measured a distance of 1 7/8" inch below a rivet line and created a stop for my circular saw with the aluminum-specific carbide blade. This cut line will become the top of a lapped joint, matching the joint 24" above it.
I learned a trick I'll pass on. If you put a piece of masking tape across the cut line the edge will be virtually burr-free.
I drilled out several hundred rivets and removed the damaged sheet metal, exposing the back side of the broken studs. The damaged metal will be hammered flat and used as a template for new Alclad material.
This is the piece I'm going to have to have made, or sacrifice an entire trailer for.
I'll remove the foam several inches above the new horizontal seam for better access for riveting.
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#365139 - 09/20/06 10:18 PM
Re: "Toybox" trailer project (7) "The final details"
[Re: Barry Wolk]
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Barry Wolk
Member
Registered: 06/17/03
Posts: 1146
Loc: Farmington Hills, MI
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9-20-2006
Took the weekend off and drove the Mark II to the Glenmoor Gathering of Significant Automobiles in Canton, Ohio.
Back to work for a couple of hours. I decided that I wasn't going to sacrifice another trailer to repair mine so I hammered out the damage to the factory-formed radiused edge piece. I think it will turn out just fine. I used an electrical knockout punch outer shell as a mandril to reform the metal. With a bit more hammering and a bunch of sanding and some finish polish I think it will look just fine.
Kind of looks like I'm disecting an elephant.
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#365141 - 09/21/06 09:47 PM
Re: "Toybox" trailer project (7) "The final details"
[Re: Shop Rat]
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Barry Wolk
Member
Registered: 06/17/03
Posts: 1146
Loc: Farmington Hills, MI
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9-21-2006 Finished product. Good enough for me.
New .032 2024-T3 Alclad siding shipped today from Kansas. Check out Airpartsinc.com. Lots of cool aviation supplies.
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#365142 - 09/22/06 08:39 PM
Re: "Toybox" trailer project (7) "The final details"
[Re: Barry Wolk]
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Barry Wolk
Member
Registered: 06/17/03
Posts: 1146
Loc: Farmington Hills, MI
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9-22-2006
Straightened the ramps by bracing the top of the ramp to the wall with a 2 x 4. Drilled a hole and installed an eyelet through the outside wall. Hooked a come-along to the furthest point on the main ramps and pulled them slightly beyond straight. Set the spring tension and the ramp system worked perfectly.
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#501432 - 04/11/08 06:53 AM
Re: "Toybox" trailer project (7) "The final details"
[Re: Barry Wolk]
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Barry Wolk
Member
Registered: 06/17/03
Posts: 1146
Loc: Farmington Hills, MI
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I was asked to bump this thread so my accident can be discussed.
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