Scoutman's 'new' Starcraft Pine Mtn on Dodge 3500
- Thread starter Scoutman
- Start date
Scoutman
Explorer
Thanks.
I'm working on sourcing the 1/8" luan layers (inside and outside) at the moment. The wall is made up of a 1/8" wallpapered luan layer, a 3/4" thick solid wooden layer, and another 1/8" luan layer with Filon on the exterior. I easily peeled back the compromised area but had to really work a stiff putty knife behind the remaining Filon to get it separated. I needed to get any material in question out in the open and decide what to do with it all. This eventually led to cutting the Filon skin completely off with a die grinder (no turning back now). I had seen some folks just peel it back, make the repair and then glue it back. I wasn't convinced that you wouldn't see the repair underneath the skin so my plan is to cut it and then when all's back together I'll put a strip of flat molding to cover the seam up.
The damage as it unfolded...
I'm working on sourcing the 1/8" luan layers (inside and outside) at the moment. The wall is made up of a 1/8" wallpapered luan layer, a 3/4" thick solid wooden layer, and another 1/8" luan layer with Filon on the exterior. I easily peeled back the compromised area but had to really work a stiff putty knife behind the remaining Filon to get it separated. I needed to get any material in question out in the open and decide what to do with it all. This eventually led to cutting the Filon skin completely off with a die grinder (no turning back now). I had seen some folks just peel it back, make the repair and then glue it back. I wasn't convinced that you wouldn't see the repair underneath the skin so my plan is to cut it and then when all's back together I'll put a strip of flat molding to cover the seam up.
The damage as it unfolded...
Scoutman
Explorer
You can see where I sanded the wood back to clean wood, the stain line that the water left, and the remaining glue layer. I made a plan, made my marks, and started cutting the rot out.
Peeled back and partially sanded. You can see how it was going to be difficult to get all the luan off and smooth back under the peeled back portion.
First cut...
Second and third cuts as well as the cut off Filon.
The aft luan chiseled away and sanded smooth. The wood is only stained so I'm leaving that part since it's solid.
Peeled back and partially sanded. You can see how it was going to be difficult to get all the luan off and smooth back under the peeled back portion.
First cut...
Second and third cuts as well as the cut off Filon.
The aft luan chiseled away and sanded smooth. The wood is only stained so I'm leaving that part since it's solid.
Scoutman
Explorer
So after a month of farm stuff getting in the way I'm back at it. I'm ready to get this thing down to the lake and out of my shop space.
The filon panel that I had cut off had a few thin layers of glued down lauan wood to it. I debated just using new filon as I had some scraps left over from the roof repair that would have worked great but I was afraid that the color would be different than the rest of the side of the camper and it being on a side wall meant I would see it. No bueno so I decided to see if I could get all the wood layers off and re-use the original filon. I used a putty knife to scrape off the big chunks and splinters and then carefully used a grinder with a sanding pad to get the majority of it off. I then followed up with a d/a sander to even things out and get the remaining off. A good wipe with acetone and it was back to good.
Here is the panel (front and back sides) sitting next to the new 1/8" lauan sheet I cut to adhere it to.
And here is sanding the wood layers off the back. It may be hard to tell but the right end is the finished product, the middle hasn't had the d/a sander yet, and the left end is what I started with.
Here's the clean and ready to glue back side of that panel
Clamped in place just to see what it looked like.
The filon panel that I had cut off had a few thin layers of glued down lauan wood to it. I debated just using new filon as I had some scraps left over from the roof repair that would have worked great but I was afraid that the color would be different than the rest of the side of the camper and it being on a side wall meant I would see it. No bueno so I decided to see if I could get all the wood layers off and re-use the original filon. I used a putty knife to scrape off the big chunks and splinters and then carefully used a grinder with a sanding pad to get the majority of it off. I then followed up with a d/a sander to even things out and get the remaining off. A good wipe with acetone and it was back to good.
Here is the panel (front and back sides) sitting next to the new 1/8" lauan sheet I cut to adhere it to.
And here is sanding the wood layers off the back. It may be hard to tell but the right end is the finished product, the middle hasn't had the d/a sander yet, and the left end is what I started with.
Here's the clean and ready to glue back side of that panel
Clamped in place just to see what it looked like.
Scoutman
Explorer
Now that the parts were ready it was time for some assembly. I still had a lot of unused adhesive left over from the roof repair so I had hoped that it was still good. After popping the top and peeling back the layer of mylar (used to keep air from getting to the adhesive surface) I was welcomed with a very hard crust of dried stuff. Well that sucks. I started cutting and found that there was good adhesive left under about a 2" thick layer of dried. I carved a bigger hole scooped out what I needed then tried to salvage the rest into a different container for the final glue up.
Dry fitting, wiping clean, and planning my strategy.
No pictures of the glue process but here's my way of getting uniform pressure on the glued up panel while it dries. Yes that's the rolling pin from the kitchen and no I didn't get in trouble. It worked great to get the initial bond of parts. :elkgrin:
And here's the final result. I cut the remaining triangles off the left edge with my bandsaw. No ripples to speak of and now it's ready to glue to the camper overhang.
Dry fitting, wiping clean, and planning my strategy.
No pictures of the glue process but here's my way of getting uniform pressure on the glued up panel while it dries. Yes that's the rolling pin from the kitchen and no I didn't get in trouble. It worked great to get the initial bond of parts. :elkgrin:
And here's the final result. I cut the remaining triangles off the left edge with my bandsaw. No ripples to speak of and now it's ready to glue to the camper overhang.
Scoutman
Explorer
Kicking this one back up. It's been a busy summer and lots to do around the farm so the camper repairs have taken a back seat for the past few months. With cooler weather and the OX-E 15 coming soon I've got to get my butt in gear and get this finished. I also really want my garage space back.
This past weekend I finished fitting the replacement board into place and got it glued and dowel'd together. I've been on the hunt for an acceptable contact paper that will match the interior wood grain color that will go on the inside portion next to the mattress. The original wall paper covering was damaged so this was my next best option. I got the 1/8" luan layer cut and fitted for the inside and am preparing to lay up the layers for assembly.
Pictures and more progress to follow.
This past weekend I finished fitting the replacement board into place and got it glued and dowel'd together. I've been on the hunt for an acceptable contact paper that will match the interior wood grain color that will go on the inside portion next to the mattress. The original wall paper covering was damaged so this was my next best option. I got the 1/8" luan layer cut and fitted for the inside and am preparing to lay up the layers for assembly.
Pictures and more progress to follow.
Scoutman
Explorer
A little more progress this weekend. Since I now had the replacement board glued and doweled in position I sanded the seam to even out the transition and to clean up the surface inside and out. I cut the inner layer of 1/8" luan and got it glued in place and clamped to dry. This overhang wall also got countersunk screwed to the support board of the overhang. Things are starting to stiffen up now. I didn't get a shot of it but there are strips of angle steel to keep things in line while they're being clamped for the glue to dry.
goofballracer
Observer
glad I found this I might have to do some similar repairs on a camper soon
Scoutman
Explorer
This past weekend I made just a little more progress. The condition of the front wood towards the corner had been bugging me. It still seemed solid and probably didn't have to be replaced but since I was this far I decided to cut the last foot of 3/8" ply off the front and replace with new. Glued and screwed and now the front end is really starting to strengthen back up.
I just placed an order from my metal supplier for a new front cap since the original one tore in a few places when I was taking things apart and it was looking a little rough.
This weekend I hope to get the filon/lauan layer adhered back to the side wall and then it should be time to start putting trim back on.
I just placed an order from my metal supplier for a new front cap since the original one tore in a few places when I was taking things apart and it was looking a little rough.
This weekend I hope to get the filon/lauan layer adhered back to the side wall and then it should be time to start putting trim back on.
Scoutman
Explorer
Slow but steadily making progress.
Here's a shot of the final lamination of layers. From out to in...
-Filon
-FRP adhesive
-1/8" Lauan
-liquid nails wood adhesive
-3/4" solid pine board (1x10 cut down)
-liquid nails wood adhesive
-1/8" lauan
-interior wall or contact paper to be added soon.
The front repair patches I made the other day were not the same thickness plywood as what was there. It was bugging me and even more so when I started fitting the metal front skin back on. I ended up ripping it all off and buying some 15/32" sanded A/C ply and now I'm sleeping better at night. I will say that when I went to take these pieces off they didn't come without a fight. That gorilla glue is serious stuff. Between it and the screws I know this should last a long time with the proper seal maintenance.
Here's a shot of the final lamination of layers. From out to in...
-Filon
-FRP adhesive
-1/8" Lauan
-liquid nails wood adhesive
-3/4" solid pine board (1x10 cut down)
-liquid nails wood adhesive
-1/8" lauan
-interior wall or contact paper to be added soon.
The front repair patches I made the other day were not the same thickness plywood as what was there. It was bugging me and even more so when I started fitting the metal front skin back on. I ended up ripping it all off and buying some 15/32" sanded A/C ply and now I'm sleeping better at night. I will say that when I went to take these pieces off they didn't come without a fight. That gorilla glue is serious stuff. Between it and the screws I know this should last a long time with the proper seal maintenance.
Scoutman
Explorer
Tons of progress this weekend. I spent the bulk of it in the shop getting this thing put back together and rolled it outside Sunday evening to clean up the shop and clear up my mind. Sorry not many pictures and the ones I took aren't that great.
The front ply replaced that's the correct thickness.
I had a sheet of 29 gauge metal siding custom bent to match the front nose cap in Polar White to match the siding. The original front metal cap was like a textured galvalume but since it tore where the staples were holding it in place I needed to go back with something different. I used a line of construction adhesive along the top and clamped it in place for 24 hrs to get started.
How the inside is shaping up...
Then it was time to clean up trim (get old butyl tape and caulk off) and start getting things put back on. After the metal was secured the top piece of trim was gooped up in sealant and screwed in place. Any exterior trim got the old screws tossed in favor of #8 stainless steel screws. New butyl tape was used under every piece of trim.
I still need to finish trimming the excess butyl tape off and reseal some other seams but the bulk of it is done and ready for a final cleanup.
My wife and I are considering going ahead and selling it and getting a Four Wheel Camper on order. We'll be looking at the details at OXE. If anyone is interested in seeing it let me know.
The front ply replaced that's the correct thickness.
I had a sheet of 29 gauge metal siding custom bent to match the front nose cap in Polar White to match the siding. The original front metal cap was like a textured galvalume but since it tore where the staples were holding it in place I needed to go back with something different. I used a line of construction adhesive along the top and clamped it in place for 24 hrs to get started.
How the inside is shaping up...
Then it was time to clean up trim (get old butyl tape and caulk off) and start getting things put back on. After the metal was secured the top piece of trim was gooped up in sealant and screwed in place. Any exterior trim got the old screws tossed in favor of #8 stainless steel screws. New butyl tape was used under every piece of trim.
I still need to finish trimming the excess butyl tape off and reseal some other seams but the bulk of it is done and ready for a final cleanup.
My wife and I are considering going ahead and selling it and getting a Four Wheel Camper on order. We'll be looking at the details at OXE. If anyone is interested in seeing it let me know.