The Wonderful World of Airstream Wing Windows

These windows are EXPENSIVE to replace. With shipping and exchange, probably a grand. So, to paraphrase Elmer Fudd, 'Be vewwy quiet, we're sepawating wing windows....'

First step in the process, take courage and watch others' ideas via uTube. I once learned how to deliver a breech lamb via uTube, so I figured someone else has gone before me and posted a video. And they had.

Second, drill rivets and remove window from trailer. 

Third, take windows to shop and remove four screws holding frame together. I thought they were going to be recalcitrant little buggers, but some WD40 did the job. 

Front of sash removed

Fourth, remove the front panel after screws are loosened. This was the easy part. Notice the shape of the gasket. Yes, I cut it but notice there's no butyl tape left on this window. This is why it was filling with water.  

The water in the window was frozen until yesterday.

Once the frame was removed (Goof Off is my new best friend. It makes old gasket material get slimy—literally melts it) from the gasket, I pulled the two panes apart.

Sash removed without too much trouble. Go slowly, make sure all force applied is vertical in orientation and use plastic chisels to slooooowly pry the glass apart.

That's 45 year old butyl tape. Still sticky but no longer waterproof.

Here are the two panes apart. 

Now, it's just a matter of scraping off old butyl tape. More Goof Off and elbow grease. After a cursory cleaning, we have a clean window, ready for new gasket material and reinstallation.

If ogres are like onions....

Yes, the saga continues. It's been quiet on the blog front as I've been woodworking for the past months. Can't work on the Silver Bullet when it's -25C. With the warmer weather (only -5 this morning) I've returned to the trailer. With a vengeance.

You see, it came with floor rot. The previous owner lied about nearly everything about the trailer (caveat emptor...). I knew there would be issues and I was prepared for the worst. Well, the worst has yet to transpire.  

I've pulled up all the floor. Been on my knees for two days. My very own pilgrimage of penance, but for what, I'm not sure. Maybe for starting this madness? 

Frame exposed. "Did you drain the water tank?" I asked. "Oh yes," he replied. The tank is FROZEN SOLID.

From my reading of others' blogs who have journeyed this road before me, a common problem is rusted frame. Usually the outriggers are the first to go. Thankfully, only one of mine will need replacing. There is a lot of surface corrosion on the frame, but that can be easily removed before priming and rust painting the frame.

The hardest part was removing the 3/4 inch plywood from the channel that surrounds the frame. I had to drill, chisel, sawsall, circular saw, prod and pray until it finally came out. Oh, and cut about 100 rusted bolts and screws.

And under the left garbage bag, a spare tire...

....that I accidentally cut through with the sawsall. First casualty of the trailer but I wouldn't have used the tire anyway. It's 45 years old. Some of the plywood, like the plywood underneath the rectangle (top right) is also frozen solid. "Any leaks?" I asked. "No, I don't think so," he said. I knew there were leaks—had to be—I just didn't know where. Turns out this is why the plywood is frozen solid in the channel. No worries. Once warmer weather hits, I'll chisel it out.

You'll notice the wheel well is removed (left side). Part of the renovation is how to seal all the water access points that developed over the 45 years. I'll be ordering aluminum sheeting, rivets, etc and fabricating patches and sealing spaces. Lots of Sikaflex 221 in my future.

The shoulder I injured in Austria skiing in 1979 (sounds exotic, right?  Alas, I hit a piece of grass and it threw me on my shoulder) is telling me that I'm not as young as I used to be. But the great thing is, I'll never have to repeat this part of the renovation.

Next step is to start removing rust. Once all the weather warms up, I'll pressure wash the entire frame and then start the painting process. Then come new water lines, electrical, windows, insulation, fans, furniture.... I should be done next week.

Stay tuned.