Did I show you guys my fall project?

[Ripsnort]

Can't remember if I did or not....anyway...
We purchased ($9,000) a used 19 year old motorhome last year, with 42,000 orginal miles. Prestine condition, except I noticed it had leaked near the large front window, a typical problem for these type of Class C's.  It wasn't until this fall that I decided to pry into the problem.
My intentions were to to do this in 3 stages:
--upper rebuild of cabover tieing into solid upper wood and cover window.
--frontal rebuild and flooring
--Sealing it up, final paint.

As I began to explore, it didn't look pretty... musty smell starting filling my nostrils as I exlored deeper. Final verdict: partial Cabover rebuild with intentions to remove the window.

 I spent about 6 hours tearing it apart, keeping the old wood in tack to the best of my ability, for later measurements. I have about 80 hours and $1100 invested so far.  What were the quotes to have an RV place repair this? $3000-$5,000 dollars, depending on the RV place.

Here are some before, during and current "in progress" pics. I'm trying to get it ready for hunting season and ski season, which we used it for last season.




Wood rot looking up the rail near window:


Floor boards of the cab over section (where the kids slept) showing the dry rot problem after tear off


Tear off complete up to the "good wood" where the rot stopped..


Old and new leading edge


Framing (looks distorted due to wide angle lens) shows the big window GONE! Cya!


Framing covered and West Epoxy system coated wood (no rotting in the future!)

[Ripsnort]

I then added some insulation to the leading edge nose (pic 1) and then attached the outter skin panel (The entire front has West Epoxy coating, no future water damage here!).

Then I added 1.5" insulfoam type 2 in the interior of the cabover, (pic 2) and then sealed it up with the interior panel (pic 3). 

This creates a very strong "sandwich", two pieces of 1/4" plywood (total 1/2" thick) and foam core (Pic 4). The kids should be nice and toasty on those cold winter nights at ski camp.









A good friend who works at an RV manufacturer in Riverside, CA went out of his way during a busy time of year to fabricate two pieces that I needed to continue on the project. He'll be getting a good bottle of scotch in the mail soon.

The first piece of filon was cemented in place on the first bedboard, then installed. Both 1st and 2nd 'extention' piece of filon-backed 3/4" was then attached with self-tapping Machine screws into the metal frame on the sidewalls.  I have it propped up in place to prevent the slight sag between the two pieces of 3/4". I will fiberglass tape these two sections from the inside.

The next step is attaching the outter piece of filon that wraps around the nose, which will cover the 2nd piece of 3/4" plywood.

(Wide angle lens distorts some views)








As mentioned before, the MH has a huge front window, and it leaked during its life somewhere along the line. There was only 1 previous owner, and I think he tried to seal it up, but of course the water damage was sealed up with it, thus dry rot.  I removed this window permanantly and framed in the hole left by the window. No more leaks there! 

I finished the interior Oct 18th (minus the molding) with a white oak finish panel and all I have left now is to put the final piece of fiberglass around the cabover, plan on doing it this Sunday. I have about 55 hours into this project so far. (Sure beats paying the price for a new Motor home!)

Interior complete except for molding, trim on the edges of the paneling:


Top portion of fiberglass filon was salvaged, sanded, primered and painted with Interlux exterior boat paint. Final new piece of fiberglass filon yet to be added.
[/QUOTE]

[Ripsnort]

Then we made the final bend around the leading edge .

First picture shows the propane heater at the far end and ceramic heater nearest, that warmed up the .06 filon to make it easier to conform and reduce chances of cracking.

Second picture shows the 2X4’s that held it underneath after sealing and screwing the edges (Stainless steel countersunk screws)

Third picture shows how we kept pressure on the leading edge. This was my dad’s idea and it worked great!

Just alittle sealing of the edges with 3M 5200 caulk and apply the eternabond tape to the edges, seams and we’re finished!
Hope to have a final picture this week-end. Depends how fast my double back eternabond tape ships.

[Ripsnort]

The final product, complete with a picture I took this past fall of a trout spitting out a hook while my son was fishing. I had it blown up with photex exterior product called Wallhogs.





Interior pic, completed

[Banshee7]

   Wow!  That is great!

[Ripsnort]

And a HUGE thanks to MT aka Midnight Tahgut, his business provided me with the new pieces of filon (that fiberglass covering) at cost! It would not have turned out nearly as neat and tidy without his help! 

[Heater]

Looks Good Rip, Enjoy it

[DYNAMITE]

Holy crap Rip!!! That's AWESOME!
Great work 

[Ripsnort]

Thanks Heater and Dynamite! You'd be surprised (well, maybe not...) what materials and methods the manufacturers use to build motor homes and coaches. I was surprised as hell to see STAPLES and glue that held this together. I probably applied overkill when rebuilding it (hey,I'm a Boeing guy, we always overbuild!), but I'll sleep well at night knowing it's not going to leak. I'm certainly glad Fleetwood used a metal frame for the walls, otherwise this rebuild may have been much more extensive.

[RufusLeaking]

Nice work.

I have garage envy.

[SunBat]

Very nice.  Love finishing touch with the trout picture.

[Ripsnort]

Very nice.  Love finishing touch with the trout picture.

Thanks! Sure beats that huge leaking, useless window that used to be up there!
>>
http://pic100.picturetrail.com/VOL767/2726312/21767624/359077741.jpg

[MiloMorai]

Nice job Rip.

But that fishing story. Come now, tell the truth, it was your fish not your son's.

[SIK1]

Way cool. 

[BMathis]

Very cool.  Nice freaking job Rip.