Thursday, May 22, 2014

Loose Ends

Now that the belly pan is complete I have some other details to take care of before turning the chassis  back over onto its wheels "Rotisserie." 

An alclad aluminum piece needs to be installed between the frame rails. 

Installed it gives a finished "look."

The 7-wire cord, (whip) was positioned prior to last piece of aluminum being installed at the "A" frame.  A grounding terminal was installed on the bottom of the frame.  These wires will be routed up into a junction box in the trailer wall.

The fender wells needed to be rebuilt on this trailer.
New ones were fashioned and installed.  
Stiffeners needed to be installed to help support the outer shell wall when it is re-installed. 

An aluminum angle piece was fashioned and positioned inside the wheel well.

Buck rivets were used to secure the angle piece to the inside of the wheel wells.

The piece will not interfere with the wheels but will provide the needed rigidity for the outside wall of the shell.
A portion of the wheel well will have to be trimmed away after the shell is re-installed onto the chassis.  The shell has an arched cut-out for the wheels.  The aluminum angle piece had to be installed so as to leave room for a future cut to match the cut-out on the shell.

Note the uncut ends of the banana wraps.  They will join and match the cut-out on the shell.  A trim piece will be installed around the finished wheel well.

Look !  Rotisserie!
The chain hoists and some persuasion was used to flip the chassis over again.

Back on its wheels again.

Moved to another position to handle some small details and installation of rivets in the "C" channel.

Looking a lot better and stronger.

Belly Pan

The outer portions of the belly pan (banana wrap) have been completed.

Now the center portion of the belly needs to be covered with aluminum.

Unlike when the trailer was built, I wanted to install aluminum in pieces this time.  That would allow access and servicing of plumbing components at a later date.

Since the belly will not be visible inside of the banana wraps I chose to cover the underside with construction grade aluminum.  Individual pieces of aluminum were cut to cover the cavities where plumbing can be accessed at a later time.  The layout for the large section forward of the wheels required that two pieces of aluminum be joined to cover the area.

The two pieces of aluminum were joined using buck rivets.

Riveting practice occured here with my new rivet gun from "Vintage Trailer Supply."

Each cavity received "Prodex" and fiberglass insulation.

All of that aluminum looks nice when fitted into position.

In the future I may decide to add a spare tire carrier near the front under the "A" frame.  Planning ahead, I fashioned and installed these brackets so that the job would be much easier.  An additional brace was added between the frame rails to support the tire against the belly pan.  Carrying the spare tire in this position may or may not work relative to ground clearance but the brackets are now in place just in case.

Before adding the insulation and the belly pan aluminum I positioned the brake wires.  Two additional wires were also installed.  One for a light to the step and an additional 12 volt circuit for future use.

The step required cutting and fitting of the aluminum.  Note the 12 volt step light wire in place.

Insulation and aluminum was then placed in each cavity as I progressed toward the rear of the trailer chassis.

The four corners were very difficult to install.
  They required me to exercise much patience and skill. 

I think that the corners were very difficult to accomplish due to the thickness of the aluminum chosen and the multiple curves involved.  I will choose a thinner aluminum product next time.

That's a lot of aluminum but it is complete!