Showing posts with label photos. Show all posts
Showing posts with label photos. Show all posts

Wednesday, March 27, 2013

Taking Stock

The past couple of days have been a chance for me to take stock of where things stand with the teardrop.  The first thing I did was clean the interior.  I went through about 10 buckets of hot soapy water cleaning the aluminum.  It was really dirty inside.  However, there were no signs of critters living in the inside.  The hatch had a boatload of caulking from various applications over the decades.  I applied a chemical that broke down the bond of the caulk and helped it peel away.

The windows were a nightmare.  The wood frames were rotten and the screen was completely rusted.  (You can see the sagging seal and the rusted screen in the image below. )  The aluminum 'cover' of the window is supposed to be hinged.  This one was completely missing, (we later found it in the cabin.)  The one on the other side had been caulked in place.  I removed all of the rotten seals as well.  I took one window frame out and left one in for reference as I begin to rebuild the wooden frame.  I will treat the 'new' frame with polyurethane to help it last a few more decades.  I considered buying a plastic framed window, but unfortunately, they are a unique size and will probably need to be specially made.  I have a window company that I would like to at least have an estimate from so that I can make an informed decision.  If it's not too terribly expensive, I think it would be worth it to have a sliding screen window.  I'd like to be able to have the light inside the cabin from windows. 

Later today, I was able to remove all of the trim along the bottom of the trailer.  I plan to replace this badly worn and broken trim with a slightly larger trim piece.  I'm looking forward to learning how to use a rivet tool.  It was a lot easier than I thought it would be to drill out the old rivets. 

You can see in this picture the old wood frame and the larger wooden frame that is used to seat the door.  I plan on rebuilding these pieces soon. 
This is the naked door with all the wood and hardware removed.
You can see by my wooden mallet all of the hardware that I removed today.  Each of those are going to be replaced by replica hardware that I've been able to find online.  It's time to start shopping for all those replacement parts!

Friday, January 18, 2013

Project Breakdown

Here are the steps I came up with in the last post.  I am going to break each of the steps down and include as many of the details as I can.  I will add specifics if I can, which I hope will make the process of completing each step easier for me in the long run.

  1. Install hitch
     2.  Take ownership of the Teardrop/bring it home
    • I will need to drive to Cookeville, TN This is about ten hours.  
    • When I get there, I'll need to fix the trailer lights and inspect the axle and wheel bearings.  If the lights don't work, I may need to use a magnetic set of lights for the short term.
    • Will I bring Jack with me?
    • Will I stop and visit with Larry, who lives just north of Dayton?

     3.  Clean and perform 'basic' structural and cosmetic repairs to Teardrop and trailer
    • Once I get the Teardrop home, I will carefully clean the interior and exterior.  
    • When the interior is clean and dry, I will inspect the underside of the trailer and floor.  Hopefully, they will be in satisfactory condition and the floor will not need to be replaced.  If it does, that sets in motion an entirely different set of circumstances.  For the sake of argument, let's say it DOES need to be replaced:
      • I will need to unbolt each of the bolts which go through the floor and through the steel frame of the trailer.  
      • Somehow, the cabin will need to be lifted off of the chassis.  
      • The floor will need to be replaced with a suitable plywood sheet.
      • The plywood sheet will need to be weather proofed using roofing tar.  (This might need to be done even if it is not replaced as a way of weatherproofing the bottom.)
      • If the cabin is removed, it is conceivably possible to 'finish' the interior of the cabin with 'large' sheet goods.  If this is the case, the entire electrical plan would have to be implemented before the cabin could be rejoined to the chassis.
      • Lastly, the cabin would be re-attached to the trailer chassis. 
    • The frame and tongue will need to be cleaned with a wire brush and treated with several coats of Rustoleum black spray paint.
    • The inside of the cabin and floor will be completely painted with high gloss exterior house paint.  This should change the aesthetics of the interior greatly.
     4.   Add 'temporary'  lighting elements to cabin and galley
    • I will install temporary lighting in the interior and galley.  I have several battery operated LED lights that should work quite well for this application.
     5.  Electrical plan
    • This is going to be one of the most challenging elements for me.  I will need to solve several problems.
      • First I will need to decide whether or not I will integrate AC and DC power into the design. 
      • Next I will need to think about the 'need' of AC devices like air conditioners, etc.  Their inclusion opens up many design obstacles such as ventilation, security and most importantly infrastructure of the electrical system.
    • Once I've decided on the above elements, I will need to layout the design.  Thankfully, I've been able to study the schematics of many builds on the forum.  At this moment I am leaning toward both an AC and DC system; albeit a simple design.  I do not think that I will include the AC unit in my design.  Here's why:
        • I prefer camping in 'primitive' sites; these often do not have power.  
        • I don't have anything against other campers, but when I 'camp' I prefer to be away from others where I can enjoy the out of doors.
        • I don't want to have to use a generator (which is often not allowed in campsites).
        • I plan to add the Fantastic Fan to the Teardrop.  This works as both a vent and a fan.  I am pretty sure that with the addition of a secondary fan in the cabin, I can create enough of a breeze to keep us cool in most conditions. 
        • Planovet developed an innovative 'power center' that I really like.  I want to integrate his ideas into my electrical plan
        • I would like to plan ahead for adding a solar panel.  I need to research this so that when I do add the solar panel I won't have to undo any of my earlier work.  If there is a way to 'add' the cable ahead of time, I would like to do that. 
    • What specific electrical fixtures will I install?
        • Reading lights in the cabin
        • Dome light with both red and white LED's
        • Porch lights: small colored LED's
        • License plate light
        • New tail lights
        • Marker lights on top of the hatch and along the sides
        • Galley Light with both red and white LED's 
        • Fantastic Fan/Vent; thermostat controlled, rain sensor, etc.
     6.  Cabin and galley design

    • As briefly mentioned above, the cabin and galley will be insulated.  The design elements will also need to include the cabinetry.  Again, the forum has been incredibly useful in developing a series of 'must haves' that I want to include in my designs.  
    • I hope to be able to create the galley cabinets out of birch plywood that I will varnish in order to preserve its gorgeous qualities; in my perfect world, I would have used the same finish for the interior.  Due to the constraints of the door width, however, I will probably not be able to finish the interior in large sheets of birch.  Instead I'll use regular BCX plywood; in 1/2 or 1/4 inch thickness.  This will add about 1 1/2 inches to the interior.
    • I am considering adding a layer to the floor too.  Not sure if this is a good idea or not. 
     7.  Install electrical system
    • Once the electrical design is in place, I will need to install wooden furring strips.  These will be adhered to the aluminum with a special adhesive tape. 
     8.  Insulation of cabin and hatch
    • The furring strips will then be the ribs that will hold the insulation panels (at least 1" of extruded styrofoam).  On top of the foam will be a thin skin of plywood panels.  The panels will be attached to the ribs via screws.   

     9.  Interior skin/hull liner installation
    • For the cabin, I plan to use a hull liner for the walls.  From what I've seen, the marine hull liners will be perfect.  It will conform to shapes and will 'cover' any imperfections in either the aluminum or the plywood skin.  I am thinking of using a light charcoal colored hull liner.
     10.  Installation of cabin cabinets
    • I am planning on painting the interior cabinets glossy black.  I think the contrast between the gray hull liner and the black cabinets will look wonderful. 
     11.  Installation of galley cabinets
    • The galley cabinets will be varnished birch plywood with silver polished hardware.

     12.  Repair aluminum skin
    • Replace rivets with smooth covered rivets
    • Replace edge and other moldings
    • Add drip gutter above doors
    • Add diamond plate to front of Teardrop
    • Install additional exterior lighting
    • Replace hatch handle

     13.  Lubricate axles and bearings
    • Research how to 'pack' the trailer's bearings
    • If needed, repair the bearings 

     14.  Add trailer elements
    • Weld/bolt stabilizers to rear of trailer
    • Weld additional support and diamond plate to the front of the tongue
    • Add 'rails' to the side of the tongue diamond plated area
    • Add a tongue box

     15.  Polish aluminum skin
    • Sand with 200/400/800 grit
    • Polish with yellow and then white pads (see Youtube video on how to do this)

My first "good look" at my Teardrop

Hans and I had been trading texts for the past few days; he was finally able to get to his garage where the Teardrop is being stored and send me some detailed images of the Teardrop.  These images served to excite, puzzle, frustrate and amused me.

Hans and I are approaching the Teardrop from slightly different angles.  He is all about building onto what is existing.  I am more of the mindset of ripping it out and customizing the whole thing to meet my needs.  Those needs, are always evolving.  Hopefully, with my new, slower approach to the project, I will be able to be wise enough to know when to stop 'thinking' through problems and planning and when to begin implementing.

Here are the most recent images I have of both the interior and exterior of the Teardrop.  I will add my thoughts and notes about them as they are posted.

 Ok, I am going to need to do some wire brush work on the tongue of the trailer; I would anticipate a good amount of the underside of the Teardrop will also need to be scraped and painted over with Rustoleum.  It's interesting to see how it meets the frame of the trailer; that hole there in the center must be where the electrical enters the cabin. 
 Yucky looking tail lights.  I'm hoping that I can add new tail lights to the tear.  I'm wondering how the skin will look when I remove those old tail lights.  It's fun seeing the old license plate.  I can't make it out, but that might be able to give me some clues on the ownership chain of the Teardrop.  I'll also be adding a license plate holder to the Teardrop.  I would prefer to have one in the center of the hatch and will have it lit with an LED too.
 Okay, a bit more of a view of the tongue.  I'm not sure what the metal angle iron is there at the right of the image.  I researched a little and found out that the triangular piece that is connected the the frame is original.  It pivots up and is stored on the small metal 'arm' that is just below the hole in the cabin.  I'm not sure how this will impact the addition of a crank down arm.  I would like to add one, I think.  Additionally, I would like to add stabilizers to the rear of the Teardrop.  I've seen where they can be bolted on, but I am not sure if I will have access to the frame in the way they are required to be added properly.  May end up having them welded along with additional 'hitch' receivers to the back and side so I can add additional elements, tables, bike rack and so on, to the Teardrop.
You can see, above, the stabilizers and the additional 'receivers' that are welded to the frame.  These receivers allow you to add all kinds of elements from tables to flag poles, awnings, etc.  You are only limited by your imagination.  It would be smart to have these designs in place when inquiring about how the cost of welding to the frame.  Mental note: plan all possible welding ideas for initial consult with the welding shop.
 Looks like those seals are going to need to be replaced ASAP.  Larry, my Tourette friend, told me that the seals of the 1947 Ford truck fit the doors to the Teardrop perfectly.  Now, where does one find a 1947 Ford truck seal?  This was also the first time I could see the plywood floor.  It looks solid.  Larry told me that I may not need to replace the floor; that impacts my decisions about how to 'finish' the interior.  If I don't remove the cabin from the chassis, I will only be able to bring sheet goods into the cabin that will fit through the door.  I also noticed the smooth radius of the wheel well for the first time.  This would be hard to 'cover' with wood, another consideration of how to 'cover' the interior. 
 Another yucky tail light.  One side note, the edge trim of the hatch looks sound here.
 Door handle hardware.  Interestingly, the door handle hardware looks completely sound.  I may be able to simply clean it up, spray it and use it over again!  I am getting my first look at the window assembly.  I still don't completely understand how it operates  I think there is to be a screen there, but that makes me wonder, how to you open the window with the screen in place?  Does it crank out?  Not sure, but that will be fun to explore. 
 Aha.  Another, more full view of the tongue.  I am glad to see that the length of the tongue is substantial.  I have plans to add a tongue box which will be part of my electrical system.  I would like to store the battery and possibly the battery 'tender' inside the tongue box.  I've seen some nice ones in the stores and online, but am considering making my own.  One additional note about this area of the tear; I am thinking of adding 'diamond plate' to this section.  It would reach from the frame up about four feet.  This would serve many purposes. One would be to 'repair' the damaged finish you can see in the image.  The other would be to solidify the skin and provide a bit more rigidity to the frame and cabin. 
 48" hypotenuse provides a substantial 'base' for the tongue box and storage 'gates.'  In addition to the tongue box, I would love to add a 'shelf' where many things, like chairs, etc, can be stored.  I have some excellent images in my idea binder of how this is accomplished.  Here is one of them.
In order to make this work, I would need to have some welding done to the chassis frame.  I'm finding that this is not that terribly expensive.  It would just make sense to have all of my 'welding' done at one time.  I'm not sure what the 12 volt receptacle is for there, but I'm curious.



 The galley.  Despite the 'historical' nature of the Teardrop, I plan to remove these cabinets.  One interesting note is that I thought this would be 'impossible.' Well, it turns out that with a $20 tool called a pop riveter, I can easily repair holes made when the cabinets are removed.  And, to remove them, one simply needs to punch the rivet carefully and then drill through the rivet with the same size drill bit. 


Another view of the interior.  Again, the floor looks solid.  The doors are interesting to me.  It looks like the 'window' is open.  I again am curious, is there some sort of 'limiter' on the window?  How does it open and close?  I'm also noticing how the door frame is stiffened by wood.  I will be interested to see how that will impact the insulating and coverage when I get to that point.
 A close up of the 'ice box' that was standard on the 1947 model.  Ice would be put in the bottom, I think, and the 'box' would have kept things chilled.  It doesn't look very insulated.  Interesting that they used steel, which rusts, for the interior.  I imagine steel has better properties for absorbing and holding the ice's cold temperatures.
A view of the area where the three burner gasoline stove would have sat.  In other images I wonder how the lower cabinet was utilized.  It seems like that is a very deep distance.  The upper cabinets are missing most of their doors and are riveted to the outside of the skin.  I plan to add a plywood 'side' to both edges when I have successfully removed the cabinets.

 
 My first interior shot of the front of the bulkhead.  I can take away a lot from this image.  First, the interior is a mess and needs to be scrubbed and cleaned carefully.  Second, the wires are shot.  I don't even know what those wires in the top right of the frame go to.  Hans did tell me that the trailer lights currently do not work.  I will need to have that fixed before I can begin the voyage north with the trailer.  I can see that there were sliding cabinet doors; one of them is missing.  I would really like to add a 'headboard' to the cabin when that time comes.  I love the way my design model turned out as you can see from the image below:
I'm not sure if we'll end up adding the 'moon' roof, but the more I work on my designs and this remodel, I do think that I will go with a light hull liner over insulation and plywood inside.  Finally, like my design, I will create a 'headboard' that has storage in it.  The headboard will be taller than the model to most likely maximize this space.

 Whoever the owner of this Teardrop was, they clearly didn't bother to do any cleaning.  I chuckle a little at the color choice of the cabin.  That turquoise blue reminds me of the 60's and my trips as a young boy to visit my Great-Grandparents in Florida.  I'm going to clean, sand and paint the entire interior super high gloss white.
 The galley.  Note the one bulb.  The original add for this model says, "Wired for electric lights."  After seeing so many beautiful designs and build logs, you can't go any more basic than this.  I would like to use flexible conduit, insulation and a plywood 'skin' to 'beef' up the galley and make it look much more modern.  I will likely use a galley light that is an LED and can be switched from white light to red for night vision protection.  The same will be true of the interior dome light.  I think its neat that the 'struts' that hold the galley up appear to be in very good shape.  I am not sure if those will need to be replaced.  It looks like a good cleaning and possibly a coat or two of Rustoleum and then WD40 will put them back into pristine condition.

 Cabinets; they look pretty simply connected.  Drilling out those rivets will be a slow process.  Key word, 'slow.'  I'm listening Larry. 
Somewhat 'big picture' image.  The galley hatch looks solid.  The sides look square and true.  It's got good bones.