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Post by youngdazza on Jun 11, 2013 18:33:52 GMT 10
Hi Ted
Having a deadline is great for keeping you motivated! The trouble with older vans is that the more you take off the more you seem to find that needs fixing! I discovered this with my Viscount Aerolite which had a similar sandwich construction and more than its fair share of woodrot! I fixed most but there's a little left however it doesn't appear to be structural. Anyway keep up the good work! Btw I'm in the hills district..
Cheers
- young_dazza
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Post by tedalley on Jun 11, 2013 20:55:40 GMT 10
young_dazza Hi.
Hills district a! I grew up around Windsor, moved around a lot, now i'm around Sutherland.
Well I've been at it all day today. I've welded angle to replace the rusted wall supports.
Then I hit it with Rust Converter including the Draw Bar.
My mate Mick will be over on Saturday to help me glue the bottom plate on the wall and get it back on the Van.
I have to work tomorrow and Thursday so it looks like I wont get to paint it with Hammered Rust Guard till Friday. (Why do we have to work?)
It's the other side next week. I'll have to reinforce that wall to take the Roll-out Awning as I don't like the idea of bolting the legs to polystyrene.
Anyway have a great night
Ted
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Post by Deleted on Jun 12, 2013 17:56:30 GMT 10
Hi Tedalley,
Watching your resto with much interest. It sure looks like you know your way around in the resto world.
As you can see from my profile pic I have a 1970 19' dual axle Franklin Regent No:2459-0 (the Franklin egg they were known as) and I am dreding having to do what you are doing.
Can't wait to see the finished product.
Cheers, DnTBear
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Post by youngdazza on Jun 12, 2013 18:40:58 GMT 10
I'm curious, before you put this side back on do you plan to try to repair the bottom of the wall where the plywood has rotten and the cladding compressed? How does the sidewall attach to the floor of the van? Is there a chassis? Sorry I'm not familiar with the construction of the Franklin.
On the Aerolite theres two chassis rails only and a plywood/polystyrene sandwich constructed floor and walls. The walls would appear to be basically tacked on to the floor with the cupboards and other furniture providing the strength!!
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Post by tedalley on Jun 12, 2013 18:50:40 GMT 10
Hi Tedalley, Watching your resto with much interest. It sure looks like you know your way around in the resto world. As you can see from my profile pic I have a 1970 19' dual axle Franklin Regent (the Franklin egg they were known as) and I am dreding having to do what you are doing. Can't wait to see the finished product. Cheers, DnTBear DnTBear Hi, Firstly you have a good looking van from your avatar. Secondly mine is a 19ft but only has a single axle Franklin egg. 3) This is my first Resto. I have worked in the building trade before. 4) I found the resto daunting before I started but relatively easy apart from occasionally needing a hand from a mate. 5) Biggest problem I'm having is the misses every time I need to buy something as I've blown the budget a long time ago and will have to contend with an internal paint job instead of new panels. 6) I had to do this as the wall was sagging at the rear and infront of axel ( have a look at drivers side photo in my first post). I cant wait to finish too. Regards Ted |
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Post by tedalley on Jun 12, 2013 19:16:34 GMT 10
I'm curious, before you put this side back on do you plan to try to repair the bottom of the wall where the plywood has rotten and the cladding compressed? How does the sidewall attach to the floor of the van? Is there a chassis? Sorry I'm not familiar with the construction of the Franklin. On the Aerolite theres two chassis rails only and a plywood/polystyrene sandwich constructed floor and walls. The walls would appear to be basically tacked on to the floor with the cupboards and other furniture providing the strength!! youngdazza Hi Ok! I'm putting a new bottom timber plate - this is 25mm x 110mm x 4380mm. Then add some skirting to cover up missing rotten ply (I had planned to replace all the ply but this is too costly and I cant get the original pattern) and paint the inside. The floor is attached to "S" channel 20 x 70 x 25mm (which is welded to the chassis). The side wall sits on and is bolted to the "S" channel and screwed to the wardrobe, end overhead cupboards, front & rear window framework, the roof ply 16mm from the top and lastly the outside alloy cladding. My Franklin has two main chassis rails and a metal framework welded to them. Pretty basic construction nothing like building a house. Hope this helps Ted |
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Post by youngdazza on Jun 12, 2013 23:10:50 GMT 10
Ted, thanks for the info on the construction of your van! It sounds a bit sturdier than my Aerolite (no surprises there!).
It sounds like you've got it all sussed out. I actually replaced the rotten plywood inside my van with new 2.7mm ply (different colour) and then painted the lot. At first I was worried that it would be difficult to get a decent looking finish but I'm actually really pleased with the result! The trick is you really need to spend the time to properly prep the surfaces - sand and undercoat all surfaces, and remove moldings where possible before painting.
Cheers
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Post by tedalley on Jun 13, 2013 19:50:25 GMT 10
youngdazza Hi.
I'm interested in how you painted it after the preparation. Did you Spray, Brush or use a roller?
I tried to use a "Renovator tool" but it was very slow.
As the mouldings are alloy I tried a grinder but the heat was causing the polystyrene to smoke so I got out the electric planer ( I had saved some old blades for emergencies) and had the wall done in half an hour.
Anyway I'm interested in how you painted it.
Ted
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Post by youngdazza on Jun 13, 2013 21:12:55 GMT 10
Hi Ted
I just used a mohair roller with some semi-gloss acrylic paint. I used a 'coffee' colour on the walls (which contrasted well with the plastic trim) and white on the internal roof lining.
Cheers
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Post by tedalley on Jun 13, 2013 21:22:31 GMT 10
Hi Ted I just used a mohair roller with some semi-gloss acrylic paint. I used a 'coffee' colour on the walls (which contrasted well with the plastic trim) and white on the internal roof lining. Cheers Great, I'll give it a go, any photos in a post of the finished inside? ......ahhhhh !!! what colour should I use? |
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Post by youngdazza on Jun 13, 2013 22:37:08 GMT 10
Great, I'll give it a go, any photos in a post of the finished inside? ......ahhhhh !!! what colour should I use? I'll try to attach a photo to this post... Attachments:
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Post by Deleted on Jun 15, 2013 12:25:06 GMT 10
Hi Ted,
Yeh she's pretty good for her age and she is as original as the day she came out of the factory - not even an external storage box, or a spare wheel bracket - (yet).
She has had water leaks over the years of course - as all old vans do - but so far she seems to be holding up ok - no signs of sagging yet.
Ted - have you ever thought of doing van 'restos' for a living - I reckon you could make a living out of it mate.
Can I ask what your budget was and by how much you think you will be over at the finish - (I'm guessing that the shower & toilet had something to do with that)??
Best wishes for the completion - can't wait to see the pics!!
Cheers, Des
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Post by tedalley on Jun 16, 2013 21:08:57 GMT 10
Young_dazza - nice van. my wife just found a 16ft like yours that she recons we should buy.
dntbear any inside shots of your van? My wife wants me to do up vans and sell them so I could get some money to finish restoring the Franklin.
You asked about budget - well firstly I paid too much for our van but I didn't notice the rot till later.
I've got all receipts and will soon start a spreadsheet to calculate actual costs but I have spent over $1,000.
Havnt bought the shower cubical yet but I've priced it on e-bay $700 - we'll have to use the porta potty for a while in the shower cubicle. Anyway that's a while away.
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Post by tedalley on Jun 16, 2013 21:17:24 GMT 10
Work done since 9/06/13
020 - Welding angle to replace rust
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Post by tedalley on Jun 16, 2013 21:32:27 GMT 10
Next I brushed rust converter and painted the side rail with Rust guard.
021 - Yesterday I got Mick over to help with replacing the bottom plate 
Mick helped me realise that the strength in the wall in in the sandwich of the outside cladding glued to the polystyrene glued to the ply. So now I have to get 2.7mm ply and glue it all over the existing ply and the bottom plate. I'll have to be very careful cause the overall width of the van will increase by 5.4mm.
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Post by tedalley on Jun 16, 2013 21:35:54 GMT 10
022 - Today I made the Handbrake leaver lock and found under the old paint "Franklin Engineering"
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Post by youngdazza on Jun 17, 2013 8:30:25 GMT 10
Looks like you had a very productive weekend! I agree its amazing how strong plywood can be when stuck against a 1" thick piece of polystyrene! The damage in my van was mostly at the curved section of the back of the van, so rather than taking the wall off like you did I repaired it from the inside then glued the ply to the polystyrene with water based liquid nails. It feels pretty sturdy and it hasnt fallen off yet  BTW tell your wife that its not worth doing up an aerolite for profit unless youre getting it for next to nothing - the resale value is generally pretty poor due to its reputation for cracking the chassis. |
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Post by Deleted on Jun 17, 2013 20:03:43 GMT 10
Hi Ted,
unfortunately not at the moment but I do need to get some for Insurance purposes so I will put some effort in that direction shortly and post them when I learn how to.
Tks for the budget info.
Cheers, Des
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Post by tedalley on Jun 18, 2013 23:10:51 GMT 10
Spent most of yesterday chasing up ply to re-cover the internal walls and ends. 023 - here I am having a micro-sleep while designing the inside layout.  |
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Post by tedalley on Jun 23, 2013 23:31:05 GMT 10
Up-date
Not much happening with all this rain. Been re-designing the interior, pulled out the night n day lounge.
Made 10 curved wall studs to go under the front and rear windows for strength (photod to come soon) 'cause i'm putting a double bed in the rear and a three sided club lounge in the front
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Post by tedalley on Jul 2, 2013 19:45:05 GMT 10
Well now that the rain's gone it's back to work on the caravan. I've lost 3 weekends, where I could get a hand, due to the rain.
So today I concentrated on the rear wall. Franklin didn't put in any wall studs below the windows, which meant that the side walls took all the weight. Below the rear window there was, on the inside, a sheet of 2.7mm ply up against the outside alloy skin.
024 - Making stud frame below end windows
024b
024d
Sadly, just as I got into the swing, tomorrow I have a job to go to. |
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Post by ForumMod on Jul 2, 2013 21:25:43 GMT 10
G'day Ted,
I've found the same in all three vans I've worked on...the Millard poptop, a Capricorn, and our latest Windsor. The Capricorn had one cross-piece of timber to carry the wiring, but it wasn't fastened to the cladding in any way. Just shows how little framework you can get away with, ay?!
I like the new curved struts. They'll certainly take the weight of anything attached to them on the inside.
cheers,
Al.
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Post by tedalley on Jul 3, 2013 18:31:53 GMT 10
G'day Ted, I've found the same in all three vans I've worked on...the Millard poptop, a Capricorn, and our latest Windsor. The Capricorn had one cross-piece of timber to carry the wiring, but it wasn't fastened to the cladding in any way. Just shows how little framework you can get away with, ay?! I like the new curved struts. They'll certainly take the weight of anything attached to them on the inside. cheers, Al. Al, Hi. Firstly - how did you just quote part of a line? 2) the reason I made the curved wall studs is 'cause i'm putting a double bed and my wife likes to read in bed slouching against the wall. I'd hate it if she fell through after all the work I've planned!!! 3) it seemed that the two side walls took all the weight (ie. roof, two skylights, end walls with large windows) 4) I plan to put four Solar panels on the roof = 80kg. Ted |
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Post by ForumMod on Jul 4, 2013 12:20:05 GMT 10
G'day Ted,
Copy and paste just the words you want to quote (it will also paste the thread details as well, so you have to delete all that junk), and then highlight all the words to be quoted and click on the "Quote" icon button at the top of the posting text box. It ends up putting [*quote]...[/quote] around those words.
cheers,
Al.
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Post by tedalley on Jul 7, 2013 19:37:27 GMT 10
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