The Welding Is Finished!

People in the Airstream world, especially new-comers (like me) often debate the merits of a complete shell-off renovation. And rightly so. It's a daunting prospect, removing the shell from the frame, etc. You quickly realize you're not even in the running for a pay grade, you're so out of your league. But hundreds have done it. One reason I decided to do it was because of the latter reason, and the wealth of info online.

I've come to the conclusion that unless the Airstream has been sitting in a heated garage for 30-40 years, not completing a shell-off renovation is like spinning the roulette wheel and hoping for a win.

When I separated the trailer, it quickly became apparent that a previous owner had dragged the bumper and in the process, bent the frame ever so slightly. Result? Cracks in some cross-beams, a lots of rust where the greatest force had been exerted. There were a few spots where most of the metal had rusted away.

Smart-neighbor Pat taught me the basics of welding and as the ever optimistic guy he is, kept stating 'we can make this as strong as the day it came off the assembly line.' And we did!

Smart-neighbor Pat and me

The worst of the rust we cut out and then welded in new plate.

We also reinforced the grey tank area. Strangely, when Airstream designed these trailers, they cut one of the cross beams to facilitate the 1 1/2 inch grey waste pipe's entry into the black tank. It made said cross beam nearly useless. Seeing as we're not going to use a black tank (going with the composting toilet option) we strengthened the frame where AS originally weakened it.

Later this week I'm going to begin the POR15 rust prevention regime. The frame will be as good, if not better than new.

One H U G E step complete. 

Gray tank sits lower left; reinforced black tank area upper right

All Is Quiet On This Western Front

The calm before the storm perhaps.

Gantries are finished. Steel ordered. Waiting for its arrival and then it's time to start welding. Did I mention I've never welded before? Well, once upon a time I had never delivered a breech lamb and I did that successfully. How difficult can this be?

Perhaps my comparison is erroneous.

I've been grinding away rust on the Airstream frame. Today, I took the angle grinder and cut out rusted parts of the frame. Smart-neighbor-Pat says with the new steel welded in, the frame will be as strong as new. I ordered the Por15 rust regimen so any rust that is left on the frame will be DESTROYED by this stuff.

Axles are ordered from Inland RV in California. Should be here within the month.

I believe the saying is, "no turning back."

Whenever I feel overwhelmed, Smart-neighbor-Pat walks over to shoot the breeze, looks at what I'm doing and says, "No problem. This can be done." I knew a pigeon farmer who said the same thing, except his was, "No question," (probably a literal translation from one of the four languages he knows).

So with the down time on the trailer, I am finally finishing my dresser. I applied the first two coats of Watco Danish Oil (light walnut) and the wood looks fantastic. This will be a beautiful piece that will probably last a hundred years.