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Topic Boards => Project Blogs => Topic started by: RockwoodMike on September 25, 2019, 10:43 PM

Title: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 25, 2019, 10:43 PM
Hello Everyone!!Ready for another full rip out project? This is my 1973 D22..Bought it off Craig's list back in June 2019..
And it was a roof cave in..Water just poured into it during the last winter..Smelled all moldy and your typical stink..That is why it need EVERYTHING ripped out of it..
Here is the first picture..Dodge 440..It ran..barely..20 mph getting it home..It was only 5 miles away at the sellers house..
I always wanted one of these things..Now it is time to do it up right!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 25, 2019, 10:47 PM
Here it is from the inside..just forward of the air conditioner is the roof cavein
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 25, 2019, 10:52 PM
Dodge 440..6 gallons to the mile..errr. It has a fuel delivery problem..That is why we couldn't get it up to 20 miles an hour, getting it home..Actually more like 6 miles the gallon!!
Being here in California, it is smog exempt because of the year it was built..So that opens alot of possibilities on the motor rebuild..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 25, 2019, 10:54 PM
Someone had laid the carpet that was showing on top of the original factory carpet
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 25, 2019, 10:59 PM
Your typical ding and mess ups to be repaired
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 25, 2019, 11:03 PM
Here it is interior from the front looking aft..You can see the roof cave in..It was "repaired" then just poured in
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 25, 2019, 11:07 PM
I am not going to bore everyone with the rip out pictures but here it is with the roof completely off and all the interior torn out..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 25, 2019, 11:10 PM
This is the right rear upper corner..Typical of everything found
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 25, 2019, 11:17 PM
So now that everything is ripped out and the roof is off..This is where I began..Making a new board frame for that upper rear panel..Using the Kreg pocket screw hole system..Got everything I needed from Lowe's for that..Liquid nails to re glue it to the aluminum
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 25, 2019, 11:27 PM
At the very top of the port and starboard wall was a 3.5x1.5 strip of blue foam ..You can see where I stripped it off..I have attached a 1x4 with glue and clamps, down the length of the wall..and the a 1x3 on top of that to create a channel for the wiring harnesses..I will take a picture of that tomorrow..
I am way ahead of this project..The rafter are all up and I am sheeting the roof now..But I will take all the pictures to catch you all up on this..
That is it for tonight..More tomorrow   
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ClydesdaleKevin on September 26, 2019, 07:57 AM
Where there is a will, there is a way!  Keep posting the pictures!


Kev
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on September 26, 2019, 08:57 AM
The other couple that are building one of these will be very interested in what you are doing!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 26, 2019, 04:17 PM
Like I said, I am way ahead on this..I am taking pictures to explain the steps I did..I wish I had been taking the pictures as I went along instead of back tracking..Anyway..
So as shown in this pic..I glued a 1x4 directly to the aluminum while it rested on top of the blue foam..Clamps and Liquid nails..Over night set up..Then glued and screwed a 1x3 on top of that..That created a ledge for the rafters to set on and a channel for the wire harness to run down the length to the back..The port wall wires run the rear brake lights.. clearance etc..
Did the same wood work on the starboard side too
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 26, 2019, 04:20 PM
here is the starboard side..see the channel for the wiring? I wish I had cleaned up the glue where it oozed out while it was still wet..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 26, 2019, 04:23 PM
Here is the starboard wall looking back at the rear corner
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 26, 2019, 04:27 PM
detail shots of the upper rear corners
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 26, 2019, 04:32 PM
With the 1x4  glued to the aluminum and resting on top of the blue foam...And the 1x3 glued and screwed to the 1x4, that created a channel for the wire harness to set into..
Those 2 pieces of wood creates a ledge for the roof rafters to set on top of ..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 26, 2019, 04:59 PM
Here is the design of the rafter..Lowe's has a nice kiln dried 2x3x96 inch

The motorhome is 93 inches wide..I made it where the middle of the rafter has a 18 inch span (flat)that is not cut...at that point it tapers to 1.25 inches out to the end of the rafter which will create the run off needed..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 26, 2019, 05:02 PM
The other couple that are building one of these will be very interested in what you are doing!

Hi Rick, where is that other couple you mentioned??
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ClydesdaleKevin on September 27, 2019, 07:29 AM
I can't wait to see all the rest of your pictures!  Most folks would have considered your Winnie a basket case and beyond repair, but you brought it back from the grave.  You sir are a hero!


Kev
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ClydesdaleKevin on September 27, 2019, 07:30 AM
Hi Rick, where is that other couple you mentioned??

"girlandwinnie."  https://www.classicwinnebagos.com/forum/index.php?topic=15070.0
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 27, 2019, 09:19 PM
Thanks Kevin for the link..Yes I looked that over awhile back before I got started on mine ..I hope they are able to pull that one back together..
I just glue and screwed the top plywood today..It is may rain tomorrow night..I just need to get the plastic on it tomorrow..Plywood is all down now..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ClydesdaleKevin on September 28, 2019, 07:03 AM
Thanks Kevin for the link..Yes I looked that over awhile back before I got started on mine ..I hope they are able to pull that one back together..
I just glue and screwed the top plywood today..It is may rain tomorrow night..I just need to get the plastic on it tomorrow..Plywood is all down now..


I'm very impressed!  That is some top notch carpentry work!

Kev
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on September 28, 2019, 10:01 AM
I like that fastening system. Do you have any issues with the 2x4's splitting at the ends?
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 28, 2019, 12:16 PM
I like that fastening system. Do you have any issues with the 2x4's splitting at the ends?
A little bit because I was using wet 2x4.I couldn't find any kiln dried 2x4 at Lowe's
Here are some pictures on how the Kreg system works..The drill tha creates the pocket hole has a tip on it that creates a hole for the shaft of the screw to help with splitting of the wood..
This system has taken over the Custom Kitchen Cabinet industries..It works great!!
So you just clamp that blue jig with the special clamp and drill away and it creates these pockets at an angle..With the construction adhesive..SUPER STRONG!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 28, 2019, 12:22 PM
And you end up with this....It draws the 2 pieces together, like if you were clamping it..I am going to be using this through out this rebuild..
Kreg has all sorts of special kits..From starter kits..basic..to full on professional systems that are bench mounted high production set ups..They produce these special screws that can be bought in bulk or 100 packs..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 28, 2019, 01:04 PM
It (I need a name for my new project..I was thinking of Sarah or Becca--Rebecca) is all covered up for the rain coming this evening..Probable the first time it will stay dry inside in years!!
Here is a shot inside..Kinda cozy actually!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on September 28, 2019, 01:10 PM
Very nice, Are you going to go with a rubber roof?
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 28, 2019, 01:18 PM
When I started on this project, I was stunned at the whole way the thing was built..The only solid piece of framing is the super structure made of steel that is in the front of it..Mainly for the upper bunk above the front cab..It frames the whole front end together..This SIP system..(Structural Insulated Panels)..Not to impressed by it..The roof had the same SIP design..That is why it sagged into the middle..and failed..

That 1x4--1x3 strip on top of the wall that was installed, terminates near the front and the construction of the wall changes from foam only (with the aluminum and luan skin) to a layer of 3/4 plywood with a 1/8 finish skin...This first picture shows the layers through this little light pocketThe second shows how it changes to plywood..above the the entry door..
 
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 28, 2019, 01:21 PM
Very nice, Are you going to go with a rubber roof?
No idea!! That is where I need guys like you to tell me what you know..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Froggy1936 on September 28, 2019, 03:25 PM
Mike, Very nice work. But as you stated, finding construction of so much light weight materials , Is a Must , What you are building will be overweight empty ! And may be heavier than tires can support ! The most important part of any RV is Gross weight . That is the reason Winnebago developed the strong light weight Materials !  But Best of luck !  Frank
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ClydesdaleKevin on September 28, 2019, 03:28 PM
No idea!! That is where I need guys like you to tell me what you know..

You can skin the whole thing with aluminum like the original...and it is durable and easy to mount/screw things to it.  EPDM rubber roofs are the industry standard now...tough enough, but you have to take more care and use lap sealant when mounting things to it.  Or you could go hog wild and go with a full fiberglass roof...super durable, but heavier and you have to deal with resin and fiberglass cloth and a LOT of sanding.

Kev
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ClydesdaleKevin on September 28, 2019, 03:31 PM
Mike, Very nice work. But as you stated, finding construction of so much light weight materials , Is a Must , What you are building will be overweight empty ! And may be heavier than tires can support ! The most important part of any RV is Gross weight . That is the reason Winnebago developed the strong light weight Materials !  But Best of luck !  Frank

It looks light enough the way he did it, with only upper wall sections being thicker plywood, etc. 

Kev
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ClydesdaleKevin on September 28, 2019, 03:33 PM
Oops!  My bad!  Mike didn't add any plywood to the walls.  The plywood in the pictures is original from the factory in the cab area.

Kev
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 28, 2019, 04:33 PM
The thicker plywood walls are what was the factory installed..I didn't install that nor am I going to do anything with that..I am glad that the plywood is there..Something solid!!
I used 2x3 kiln dried DF wood..Before I cut them, they weighed 4 pounds 12 ounces each..Then cut off about 15 ounces with the taper cut for the rain run off profile ..
But lets round it of to 4 pounds each..I used 18 of them..Doubled up at the end wall and front transition..That is 72 pounds..
I used 5 sheets of ACX plywood..About 20 pounds?? each..100 pounds..
Maybe 20 pounds for the blocks made between the rafters..
And the 1x4--1x3 stringers25 pounds??
Right at 215 pounds for everything..
I used this postal scale of mine..But could not get a shot of the display..Just too sunny to see it..

Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 28, 2019, 04:56 PM
I was curious of the original weight of the factory roof..here is a section of it in all of it glory!!
3 feet length by it's full width..I put it on my bathroom scale (I brought the scale outside..not the panel inside to weigh it :)rotflmao )It weighed 25 pounds..Taking off 21 feet of roofing would be 7 of these panels in essence//25x7 equals 175 pounds..
Now I dont have any insulation nor the final inside panel sheeting yet..that will add some
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: yellowrecve on September 28, 2019, 10:46 PM
Strength is in the design. Your doing fine. Put some backing in for your overhead cabinets and walls to attach to. That will add strength.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ClydesdaleKevin on September 29, 2019, 06:58 AM
Hey Mike.  How is the floor in your Winnebago?  Did you have to replace any of it?  If you do, now would be the time to replace all the rubber fuel lines at the top of your fuel tank...so you won't have to drop the tank later.


Kev
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 29, 2019, 06:20 PM
Hey Kevin,How is the floor?? It needs to be replaced..I am finding out as I go, that there is NOTHING on this motorhome  that isn't going to need to be replaced, repaired, fixed, altered, or any other word you can think of!!This is one of the rot spots of the floor..The second pic shows the drivers floor board..Sunlight is shining through that big dent..I need to look into that..The fuel tanks will need to come out..Neither of the fuel sending units worked and there was that fuel delivery problem, trying to get it home at 20 miles an hour..Cleaning out the tanks will be something I want to do

I have other pics and I will post them tonight..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 29, 2019, 10:01 PM
Strength is in the design. Your doing fine. Put some backing in for your overhead cabinets and walls to attach to. That will add strength.
I need to set up the floor plan for everything so that I know where to install the backing..What cabinets will go where..What walls to make at what location..I need to draw out a good floor plan..Check this "backing" out from the factory..A 20 gauge sheet steel insert glued to the foam..Then a screw was driven into it..It worked..The pics show were the shower stall was..those 2 strips of vertical steel mounted the walls around the stall..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 29, 2019, 10:24 PM
This is what I will do next..Kinda burnt out on the roof ..It has the plastic sheeting on it and it will be good for now..The lower left front wheel skirting..It is bent!! Maybe a tire blew out and flung it self around..So I have the corner curved trim off and working on the horizontal trim..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 29, 2019, 10:31 PM
That horizontal trim just pulled off by hand..Because the wood behind it is gone..rotted..Then the staples holding the trim after the wheel well area actually have some wood there..I don't have any pliers that can reach in deep enough to grab the staple..So I used a die grinder with a cutting wheel and just very carefully ground off the head of the staple..Worked pretty good actually with minimal damage to the aluminum trim..And was able to get the trim off..That whole wheel well section is just hollow..Is is all going to need to be rebuilt..I ran out of daylight to take more pictures after the trim was off..More tomorrow
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on September 30, 2019, 06:31 PM
I wonder if it was someone fighting to get a tire out from under there when it was not quite up high enough? Wouldn't take much yanking on a tire to bend that thin metal.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 30, 2019, 07:34 PM
Hey Rick..
A bent area is the least of my problems!! The sill stringer, made of wood is gone..rotted bad..That is what connects the wall to the floor!!..It needs to be replaced bad..I have a plan and it won't be too hard to accomplish..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on September 30, 2019, 07:38 PM
With 2x2 studs, I will stilt the ceiling to the floor..Holding up the wall..That holds the wall up till I get a new sill stringer in there..Then I am going to rebuild the lower area with steel..That is the plan..It will work!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ClydesdaleKevin on October 01, 2019, 07:30 AM
With 2x2 studs, I will stilt the ceiling to the floor..Holding up the wall..That holds the wall up till I get a new sill stringer in there..Then I am going to rebuild the lower area with steel..That is the plan..It will work!!

Sounds like a good plan!

Kev
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 01, 2019, 09:02 AM
I would use aluminum for two reasons, weight first and foremost and rust second. You are attaching aluminum siding to it and aluminum on steel is galvanic corrosion big time.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 01, 2019, 09:04 AM
Looking at how this thing was constructed as you are laying it out you can definitely see it was never designed to last more than ten years. They knew darn right well it was going to rot.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 01, 2019, 10:05 AM
I would use aluminum for two reasons, weight first and foremost and rust second. You are attaching aluminum siding to it and aluminum on steel is galvanic corrosion big time.
You have a good point in regards to weight and corrosion..I need to think this through..If i was to use steel for the frame, I could weld it..I don't have a welder that can weld aluminum..Concentrate on making the steel frame as light as possible..Use galvanized steel for rust prevention? Maybe a strip of black butle tape as an adhesive and separator to keep the steel from touching the original aluminum siding?..That original sill piece is sized at 1.5x3.5..But it is some sort of hardwood..The only real hardwood available around here is oak..1x4 that would be glue laminated together to create that new sill is the only idea I am coming up with..That skirting below the floor line didn't stand a chance to last long..There it is just being clobbered with rain and stones being kicked up from the tires..The other side of the motorhome is pretty much the same story.. Just no original dent as was shown on the left side..I will be working on it..More to come 
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 01, 2019, 12:55 PM
You can still work with wood, there is a product out there called CPES and I used it many years ago working on boats. I used to buy it from an outfit in Washington State called Rot Doctor but I believe they changed hands because they were always great people to talk to but the last time I tried to talk to someone there they were flat out nasty! I did some research and found the original maker of the product and he is still selling it. I forget his name, it is on my computer somewhere but do a search for "CPES Epoxy" and you will come up with a lot of good information. It will make most wood pretty much impervious to water and rot. Within reason of coarse.


Here is a link to the original maker of the CPES and a lot of info on it and some of his other wood restoration products.


http://www.smithandcompany.org/CPES/ (http://www.smithandcompany.org/CPES/)
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 01, 2019, 12:58 PM
This epoxy and Fillet filler would be good for you to use in places where it is too hard to get to the rotted wood or there is just a small section that is not structural.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 01, 2019, 02:44 PM
Check this photo out..This is one of the main reasons that these coaches are so rare anymore..And when you do find one, it is way too far gone for consideration to restore..
This is the siding just aft of the entry door..do you see a major problem here in regards to how it was installed?? When water would run down the wall, unless the aluminum horizontal trim piece was perfectly sealed..the water would actually run INSIDE to the walls..The brown siding should have the white siding on top of it to shed the water..In this configuration, it would draw it in..And it would be trapped to rot the wood..Come on..a little common sense is really missing here..You tube is loaded with RV repair videos..There is one guy that has a business out of Georgia that specializes in repair of the shoddy workmanship that comes straight from the factory..Especially the roofs that fail during the warranty period ..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: c farmer on October 02, 2019, 06:04 PM
WoW what a project.  I need to replace the ceiling in my bathroom.  Not sure on how to do it but you have me scared now to tear into it. . 
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 02, 2019, 09:20 PM
WoW what a project.  I need to replace the ceiling in my bathroom.  Not sure on how to do it but you have me scared now to tear into it. . 
Believe me, I know what I am doing..I have watched at least a half of a dozen videos on you tube on RV repair :)rotflmao And besides to add to that I played a RV repairman on TV..!!
The only advice from me on the ceiling..Go slow and try to bring down the ceiling in a way that you can use it as a template to make the new ceiling piece..Here is a couple of pics for the front right corner..The second pic shows up into the fender where the 2x4 sill stringer use to be..Nice fresh plywood..Finally!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 02, 2019, 09:24 PM
I did get something that I won't have to repair, replace.. These 2 propane tanks feel as if they are full!! Who would have thunk it..That other pic shows that sill again..rotted..
Can't wait to get this all ripped then I can start rebuilding..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 07, 2019, 09:03 PM
I have real problems now..Investigating that big dent on the drivers side, I found all of this..Everything is just rotted..I think the dash will need to come out to fix this and that involves a bunch..Including removing the front windshield frame..Didn't know it was going to be this bad..

This is going to be a big challenge..I have cut out the instrument panel..Just cut the wiring out as needed..Everything under the dash was just a big hack job of splices and rework..I will rewire this whole thing easy enough..rebuild the dash..Everything
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 07, 2019, 09:08 PM
Oh and by the way...I love a challenge like this!!  It really is'nt going to be hard to do..I spent about 2 hours just looking this all over and how it is put together..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ClydesdaleKevin on October 08, 2019, 06:58 AM
Oh and by the way...I love a challenge like this!!  It really is'nt going to be hard to do..I spent about 2 hours just looking this all over and how it is put together..

Thanks for all the detailed pictures!  This is a great project, and a lot of people are going to benefit from this as they restore their own Winnebagos.

Kev
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 08, 2019, 09:05 AM
Thanks Kevin..I appreciate your encouragement..I will be taking plenty of pictures..You can look forward to that..Mike
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 08, 2019, 10:29 AM
Mike, Here is a video from a couple that is doing the same as you, or they were. They never finished the videos so I have no idea if they finished the project or not but in thid video they show the windshield removal and apparently it is not hard.


https://www.youtube.com/watch?v=uc7D6Omq1iQ&feature=youtu.be (https://www.youtube.com/watch?v=uc7D6Omq1iQ&feature=youtu.be)


Here is part two and three


https://www.youtube.com/watch?v=RghxnS6VY2Q&t=1s (https://www.youtube.com/watch?v=RghxnS6VY2Q&t=1s)


https://www.youtube.com/watch?v=fT41OLB1c5c&t=33s (https://www.youtube.com/watch?v=fT41OLB1c5c&t=33s)
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 08, 2019, 10:49 AM
Hi Rick,

Thanks for the links!! I did watch this series when I just brought the motorhome home..Thinking that mine will never be that much to do..But video one shows the results of the face removal..You will be seeing mine soon enough..They had the same leaks at the front lower part of the side windows..All plywood in there and that is part of what holds the dash in place..Metal brackets screwed into the plywood..My plywood actually had mushrooms growing out from it!!

Mike
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 08, 2019, 10:54 AM
The last of the 3 videos was uploaded in Jan 2018..Nearly 2 years ago..I don't know what to think..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 08, 2019, 01:58 PM
Yea, it's a shame they did not follow through but from what I can gather they are in the film industry so I am thinking that maybe work got good and either they sold or scrapped it or just got to busy.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 08, 2019, 10:11 PM
I put the front end up on stands..Those are the Harbor Freight heavy duty stands and I have them all the way down when it comes to the height adjustment..Much safer and it still gave me about 5-6 inches higher than when the wheel was on..I wanted to get under the left wheel well and see what caused the big dent in the side wall and floor board..Pretty sure that a tire blew..The tread caught the emergency brake cable and yanked it down ward..Bending everything..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 08, 2019, 10:20 PM
That electrical cable for the headlight is not original..Another hack wire repair..And the emergency cable looks yanked..Tire just blew and flung it self all in there
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 08, 2019, 10:26 PM
Here is a shot of it looking forward..Oh YEA!..Then you just take all the parts and put them in the back..Compare these pictures with what I showed at the first of all this!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 08, 2019, 10:42 PM
Working on removing the face..The grills are mounted with their own screws..The perimeter trim around the grill does nothing to hold the grill on..The screws around the grills and headlights were pretty much just rusted snap off..They were originally about 1.25 inches long and go all the way to the metal shell..Holding on to the skin of the face..This poor motorhome must have just sat out in the rain without ever having any kind of cover on it
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 08, 2019, 10:55 PM
The skin has a blue foam backer but the foam is not glued to the metal shell..Peels right off..You just slide a 4 inch drywall trowel in between and it lifts right off..
Need to get the windshield frame out now before the face skin comes off..The screws holding the windshield were rusted out along the top edge..Bottom edge screws came right out but the ones along the vertical sides are frozen ..They go into a structural steel piece..I will show that tomorrow.. Maybe get the windshield out tomorrow too..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 09, 2019, 10:19 AM
Are you using one of those smaller impact drivers on the screws? I have found they work wonders on the rusted stuff. As long as the bit has something to grip.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 09, 2019, 08:22 PM
Hi Rick,
There wasn't anything I could do to work out these screws holding the windshield frame in..The Aluminum frame is screwed to a steel frame of the coach..This created the worst electrolysis welding together that I have ever seen..Using that 4 inch stainless putty trowel, I was able to hammer it in between the 2 metals. Moving it down the frame about 1/2 inch at a time..Finally was able to create a separation between the steel and aluminum..But I had to take a Dremel grinder with one of those flex extensions on it ..And a grinding stone to grind off the head of the screw...
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 09, 2019, 08:29 PM
Using this stone grinder..Shaved off the head of the screw..Then with a chisel, just slightly bend the aluminum frame above the shaft of the screw to clear it..I will straighten the frame later...I just created a 1/8th inch lift to clear the screw..There was 3 screws on each side..Had to do this on all six screws!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 09, 2019, 08:38 PM
I was ready to punch it out..The suspense must be killing you!! :D    placed this rope across the top to catch it if it fell out..I didn't have to worry about that at all!!This frame was so glued in...WOW!!..I just worked around the perimeter as best as I could with a trim knife to cut the seal..Then with a plastic hammer..I worked the bottom of the frame..Just a bunch of real light blows all along the bottom and it started to move!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 09, 2019, 08:49 PM
So here I am running in and out of the motorhome..Pounding the frame with the plastic hammer then jumping outside to see how it was going..Finally had enough gap to get my fingers into the bottom edge and I untied the rope..Those center strips at the middle top and bottom of the windshield frame are NOT welded to the frame..But I took the screws out holding them just to wiggle them some to help break the seal of the frame.. Finally popped totally loose and I lifted it down to the ground..It weighs about 75-80 pounds..IT IS OUT!! I did this totally by my self..So if anybody else is doing a project like this and has help..it can be done..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 10, 2019, 08:27 AM
The ones in that video are out in the Arizona desert and I will bet that the unit never left the desert so I will also bet all of the seals and caulk on theirs was dried out plus no water to cause the electrolysis. That is probably why theirs just came right out.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 10, 2019, 10:09 PM
In those videos, it was shown the same damage to the front corners from water getting in..Saying that the windshield frame just popped out..I am not buying that..After going through what I have done so far..it is a TON of work..All of those screws that had to be ground off..etc..It is not as easy she was making it sound even in the best of conditions..
If anyone is thinking of doing this same project..You are in for some work..But do it slowly and walk away for awhile if you get flustered..DO NOT reach for a bigger hammer if something is not coming apart like you hoped it would..This motorhome was put together very quickly in a factory new setting..For this one, it has been 46 years since..All that time to rot and rust..Just be patient with it..It is actually faster to go slow with it ..If you are trying to rip it apart fast, you will screw things up which will take longer to repair..Okay..let me hop down off my soapbox..
The water nozzles and the pivot points for the windshield wipers need to come off ..Here is the laid out parts
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 10, 2019, 10:18 PM
The front skin is in 2 pieces..Around the perimeter are screws here and there that need to be removed..Most were easy because they were either missing or screwed into rotted wood..The 2 shown in the 3rd picture were easy because they had never seen water being located under that aluminum trim piece that covers the center
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 10, 2019, 10:28 PM
The left (drivers) side gave me a little problem..There was one screw..frozen again that went through the skin..wood..then metal that I couldn't get out..Just ground off the head..But the screw was still holding on to the wood that is glued to the skin..With my trusty 4 inch trowel blade..just slid it between the skin and the wood..working it slowly apart..finally just let go and off it came leaving the wood..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 10, 2019, 10:34 PM
Here is the back side of each piece..With the rotted wood, you can easily use it to create the template for the fresh wood..Last pic shows them set aside
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 10, 2019, 10:42 PM
Here is the face totally without anything..It is solid but rusty..I really like the fact that it is solid!! The metal skin is welded to the frame..No need to remove it for anything.. What I was thinking in regards to the repair of the rust..Sand it all down and then apply a bed liner spray in coating on it..super protected and where the grill shows the black would look awesum!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 10, 2019, 11:01 PM
So to sum this up..In order to get to the wood rotted on each front corner..you have to remove the dash..in order to remove the dash..you have to remove the fron skin to get to several screws holding the dash that are located under the skin..In order to remove the skin..you have to remove the windshield frame..
All the screws were out..on each --side along the top..everything so I thought..But there was this bracket on the bottom that needed to be released..Then it just lifted right out..Easy,RIGHT!! :)clap
Bunch of work on everything..If I have it wide open like this..Lets get it done!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 10, 2019, 11:05 PM
Finally!! Full exposure of the rotted corners :'(
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Elandan2 on October 11, 2019, 06:33 AM
I have to ask, are you going to remember where all those screws go?   :D
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 11, 2019, 08:33 AM
What screws? Most of them broke off. :D  I doubt that he cares, once all the new wood is put in and everything starts to go back together I am sure he will be a bit more precise than the factory was.


Mike, In thinking about that video you are probably right since that unit had a lot of the same rot as yours.
I am curious why you use a grinder on the screw heads instead of a drill? I usually drill out the top of the screw and that does not damage the fixture.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ClydesdaleKevin on October 11, 2019, 06:26 PM
Wow!  You are going for a full resto!  Awesome!  Now would be a great time to replace the heater core, since you have the dash out and easy access to the heater box.


Kev
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 11, 2019, 09:14 PM
What screws? Most of them broke off. :D  I doubt that he cares, once all the new wood is put in and everything starts to go back together I am sure he will be a bit more precise than the factory was.


Mike, In thinking about that video you are probably right since that unit had a lot of the same rot as yours.
I am curious why you use a grinder on the screw heads instead of a drill? I usually drill out the top of the screw and that does not damage the fixture.

I tried to use a drill one time around the vertical frame of the windshield..Maybe my drill bit was dull or something, but it just wouldn't cut it at all..The corner screws would have been impossible to get a straight shot..After so many screws, each of the trouble screws, I just reached for the grinder..I did do a little damage to the aluminum frame of the windshield.. but I can fix it.. 
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 11, 2019, 09:16 PM
Wow!  You are going for a full resto!  Awesome!  Now would be a great time to replace the heater core, since you have the dash out and easy access to the heater box.


Kev

I will be getting to that..There is nothing that won't be needing attention on with this motorhome..Grab some popcorn!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 11, 2019, 09:22 PM
Got to clear some more stuff out of the way..Emergency brake handle comes out and the cable is laying on the ground..This floor under the drivers area will need to come out completely..There is no way to straighten that out..Finally got a shot of the damage with the emergency handle out of the way..It looks like a 300 pound bowling ball was dropped on it..I was thinking how it would be nice to set it up where the floor could be unbolted and lifted out when ever service is needed on the brake master cylinder..Got to get out all the scrap metal first to see how I can do that..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 11, 2019, 10:03 PM
Here is the steering column tilt adjuster thingy..I think this is the one and only thing on this whole motothome that I won't need to work on..That is one stout piece of machinery!!
I am just getting things out of the way..Just got to figure out that floor..What a mess..it is pretty much welded in all around the perimeter..That is about it for tonight. Got off work late tonight..didn't get much time with it..Weekend is here!!
 
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 12, 2019, 07:43 AM
Is there a dark stain in the middle of the drivers seat? I figure when that tire let go and the floor got waffled like that the driver definitely had an OH SH** moment! To their credit they must not have slammed on the brakes since the unit is not crashed.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 12, 2019, 10:57 AM
Is there a dark stain in the middle of the drivers seat?

What do you want me to do..Go back and check it!??!..I did notice that the air inside the coach did freshen up a bit after I took the seats out!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 12, 2019, 04:21 PM
 :)rotflmao :)rotflmao :)rotflmao :)rotflmao :)rotflmao :)rotflmao
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 12, 2019, 10:01 PM
Here is the tear out the heater plenum..Upright brackets that held the heater box..The plenum was held to the heater box on the far right side..After that it just floated..No other connections and it just sat on top of the fan shroud box..This must have been a gigantic rattle under there going down the road
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 12, 2019, 10:08 PM
Here is where the plenum was setting on top of the fan shroud..And it happens to be the very last piece of factory original carpet left in the coach..It is now totally empty of that orange stuff and this is where it ended up at..the bottom of the trash can :)clap
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 12, 2019, 10:17 PM
And here is the fan shroud popped out..Every screw holding it came out with ease..Except the very last one. $@!#@! .It stripped out and you can see on the right side, the die grinder with the cut off blade..The shroud was stuck down with sealing tape..Just had to do a little prying to get it to break loose..Alright..I am done now..There is nothing more that needs to come out..It is time to get some repairs going..I ran the shop vac over everything..This whole thing is just so dirty!!..I am going to do the right side repair first to build my confidence ..The floor board is in great shape and nothing will be needed on it..Just got to get that wall repaired..More tomorrow
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 13, 2019, 06:04 PM
DAMN!!!!! That is about as complete as you can possibly get as far as a tear down! Even the fan shroud. Just remembering where all this goes is going to be monumental!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 13, 2019, 09:32 PM
DAMN!!!!!
Rick, your word is perfect!! Can't describe it any better!!
Now, the next few photos are not for the faint of heart..These will make or break anyone else thinking of doing this..I made some large mistakes today..But I can fix it easy enough..If I had just looked over on how this is built a little better, I would have had much more done today..But I screwed up..Now maybe the children should be escorted out of the room..Maybe some might be offended..And of course you all know that I am just kidding around!!  But don't say I didn't warn you!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 13, 2019, 09:41 PM
I tried to remove this steel panel..In order to have access to the rotted wood..I went down to Home Depot and bought some steel cutting Sawzall blades..thinking I could cut the welds..Pull the steel out..fix the wood..then install this steel back into it's place..Not a chance!!Don't try to do this..Those welds are extra hard and it just won't work..So then I tried to cut just the perimeter with the die grinder..Mistake again..I shouldn't have done that..And the rest of the photos will explain why..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 13, 2019, 09:49 PM
With the door being in a place as it is, this panel is a short lower section..The seam of the outside wall is just a slip in..The lower slips into the upper..Inside the fender wells are several screws that secure the steel framing to the plywood of the wall..So I took down the wall..Just the bottom half..It actually fell out after grinding those screws off!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 13, 2019, 09:53 PM
This is where finally I was able to get out the rot and make some straight cuts to create a clean replacement..This shows where the rot was and how easy it will be to replace it with some CDX plywood..Believe me..I have this under control..I can fix this!! That is a new piece of 2x4 pressure treated..That is what I will use for this project to fix all that sill wood
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 13, 2019, 09:55 PM
Now remember..This is the "Easy side"..I really don't know how I will fix the other side yet..But I learned how not to do it on this side..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 13, 2019, 10:02 PM
Just remembering where all this goes is going to be monumental!
Getting it all back together will be easy!!..Just read this thread backwards..Seriously!! The fan shroud will be the first to go back in!! :)rotflmao
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: LJ-TJ on October 14, 2019, 06:36 AM
Amazing, Flipping Amazing. This is going to help a hole lot of folks. Probably encourage those who are a little timid to start to start. Well done mate, well done. Keep up the good work.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Elandan2 on October 14, 2019, 06:54 AM
Looking at the "other" side, couldn't you use a jack to push the floor up into position again? I know in ours, there is a couple of small square tubes inside the floor to provide support for the seat. Then the outer channel could be bent back into position from the outside.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 14, 2019, 08:57 PM
Looking at the "other" side, couldn't you use a jack to push the floor up into position again? I know in ours, there is a couple of small square tubes inside the floor to provide support for the seat. Then the outer channel could be bent back into position from the outside.

I will get back to you on that..The metal is so stretched, I don't think it would push back flat again..It is going to take some hard work to do that fix..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 14, 2019, 08:59 PM
Amazing, Flipping Amazing. This is going to help a hole lot of folks. Probably encourage those who are a little timid to start to start. Well done mate, well done. Keep up the good work.

Thanks for the words of encouragement!! I am just wondering how many people are reading all of this..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 14, 2019, 09:11 PM
In regards to this repair section..The new Plywood is going to be glued to the original foam..I did a test glue up, because I saw another thread of the attempts to glue plywood to foam without the foam being eaten by the glue..Liquid nails is what I used to glue that top board to secure it to the aluminum skin..Worked great for that..But never used it for foam to plywood during the roof construction..Liquid nails has reformulated the glue as a latex base..I think it use to be a hydrocarbon base..But it works fantastic..Small piece of ply to a scrap piece of foam..Over night clamp..I am totally blown away on the strength of the bond..Did the usual zig zag application..Mated the 2 pieces and kind of wiggled them back and forth..That spread the glue flat and then clamped over night..Worked Great.. :)clap   
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 14, 2019, 09:23 PM
I have a Wild Hair idea.. Hm? Fixing that port wall..Drop the bottom half like I did with the little starboard side piece..I need to think this through but it might work..Stilt the ceiling up to hold it ..2x4 from ceiling rafter to floor..Screwed together at both ends with that pocket screw system..Maybe 5-6 of those..The wall at the midpoint line is nothing but foam..Cut the foam with that 4 inch putty knife that I have shown earlier..That blue foam is easy to cut..Take out all the mounting screws..I need to look at the back corner to see how that is attached..I need to fix the first panel before I touch this full length wall..But that is the idea..Get it out and lay it on the ground on top of moving blankets..Doesn't get scratched that way..And then repair everything..I think that is what is going to happen..What do you think?? Hm?
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: tmsnyder on October 15, 2019, 07:06 AM

Oh don't worry.  We are all reading it.   We just think you are nuts! :)rotflmao :)rotflmao


I'm really enjoying this thread  :) :)ThmbUp





Thanks for the words of encouragement!! I am just wondering how many people are reading all of this..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 15, 2019, 08:23 AM
If you go to this thread, http://www.classicwinnebagos.com/forum/index.php?topic=15070.0 (http://www.classicwinnebagos.com/forum/index.php?topic=15070.0) , You will see that they took out the entire lower side wall and there are some steel beams in there. I think the two of you can be learning from each other on how to do your rebuilds. Although we have not heard from them lately and you seem to be way ahead of them in some respects.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 15, 2019, 10:52 PM
If you go to this thread, http://www.classicwinnebagos.com/forum/index.php?topic=15070.0 (http://www.classicwinnebagos.com/forum/index.php?topic=15070.0) , You will see that they took out the entire lower side wall and there are some steel beams in there. I think the two of you can be learning from each other on how to do your rebuilds. Although we have not heard from them lately and you seem to be way ahead of them in some respects.

I have read and re read that thread and on post 6 it shows this big rotted area and I can not figure out where that section is..The big thing on this is to preserve the skin..It would next to impossible to re create it..And I am seeing it cut up..There really isn't any reason to do that..I just wish they were back on this with any kind of update..Would be interesting to see it and how it is coming along..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 15, 2019, 10:58 PM
Small progress report :)clap Actually going back together some..I made the new plywood piece that replaced the rot on the right side of the coach..With a typical paper template and using CDX plywood..Then gluing it up like crazy..You got to be careful doing a big piece like this..It will float on the wet glue as you are setting the weights on it and go out of position..After setting all the dumbbells and water jugs on it, it had shifted some..I was able to tap the edge and it re positioned itself..That will set over night..I sanded the blue foam lightly just to clean it up using that palm sander..All it really did was remove the original glue remnants..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 15, 2019, 11:02 PM
I am going to use this pressure treated wood to rebuild the lower skirt fender well area..Using that pocket screw system and the construction glue..That will never rot away!! :)clap Those two open areas will be stuffed with blue foam..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: LJ-TJ on October 16, 2019, 07:05 AM
 :)ThmbUp WOW!Nicely done.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Elandan2 on October 16, 2019, 07:46 AM
Actually, you can get new aluminum skin.  https://www.all-rite.com/aluminum-siding-metal.html (https://www.all-rite.com/aluminum-siding-metal.html)
I can imagine how much the shipping would be, but...
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 16, 2019, 09:00 PM
Actually, you can get new aluminum skin.  https://www.all-rite.com/aluminum-siding-metal.html (https://www.all-rite.com/aluminum-siding-metal.html)
I can imagine how much the shipping would be, but...

Starting at 8.40 a square foot!! Not a lineal foot..SQUARE!! Lets see..About 4 feet wide x 21 feet long..Over $700 just for the sheet..Now ship it..Right!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 16, 2019, 09:04 PM
I glued and screwed the frame work together..Pocket hole system really clamps the joint..With glue in between.WOW!!And then test fit it..Then glued it to the bottom of the new and old plywood..And the skin..We will see how it looks tomorrow
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 16, 2019, 09:10 PM
:)ThmbUp WOW!Nicely done.

Thanks..!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: tmsnyder on October 17, 2019, 07:13 AM
That Kreg system for pocket screws is really handy.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 17, 2019, 08:21 PM
I welded back in that sheet metal that I cut out earlier..My mistake that I made earlier..Notice that it is a far away shot..I am a terrible welder especially with sheet steel..But it is back in as that sheet metal has several holes to set screws into the new plywood..This second pic is a fix where the skin had separated from the foam..Reglued..I think tomorrow will be the day the repaired wall panel will go back in :)clap
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: LJ-TJ on October 18, 2019, 09:02 AM
Just noticed the gas tank behind the steps. Interesting. You got me hooked. Great job. Following this is better than watching "Dallas" Oooops Not sure you guys would remember the tv show Dallas. Hehehehe
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 18, 2019, 10:56 AM
Just noticed the gas tank behind the steps. Interesting. You got me hooked. Great job. Following this is better than watching "Dallas" Oooops Not sure you guys would remember the tv show Dallas. Hehehehe

I bet it was YOU that shot J.R...It had to be you..During that summer we all had to wait till the fall season..Vegas was laying down odds and taking bets..Even the cast members of the show didn't know, because they produced 3-4 scenes reveling the culprit and only the producers knew which scene they were going to use..Magazine covers with"Who shot JR" With Larry Hagman grinning on the cover with his cowboy hat..I do remember..And both of us are getting old!!
Yes ..2 gas tanks..The front one is an after market tank..Probable both filled with rotted gas..I haven't checked them yet..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 18, 2019, 10:18 PM
I happen to own a CNC Plasma steel cutter..BWAAA HAAA HAAA coff coff coff weeze :)rotflmao Got all the info on how all of these type of machines work from cnczone dot com and decided to build one for myself!!
I needed to make a new skin for the inside of the fender well..Instead of the original aluminum, this is 16 gauge galvanized cold roll steel..Heavier but lots more durable for all that happens in the wheel well..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 18, 2019, 10:20 PM
Here is the new compared to the old..The old is bent because the whole panel dropped to the ground when I first took it out D:oH!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 18, 2019, 10:24 PM
When I tried to fit the panel up, it wouldn't fit..Couldn't get it to lift into the original seam seal..It was hitting the new plywood on the steel frame..Little bit of trim and it fitted right in..It is in!!! :)clap Fully screwed into place..Solid as a brick!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 18, 2019, 10:30 PM
That Kreg system for pocket screws is really handy.

I plan on using this Kreg system through out this restore..New cabinets..fixing these walls..I don't know how else it was done..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Elandan2 on October 19, 2019, 07:37 AM
You built your own plasma table, I'm impressed. Now you just have to build a roller to make the siding and you're all set.  :)
https://www.youtube.com/watch?reload=9&v=SWgLTJJ-RGU (https://www.youtube.com/watch?reload=9&v=SWgLTJJ-RGU)
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 19, 2019, 08:54 AM
https://www.youtube.com/watch?v=msLi_9I_ikU
Here is a goal worth striving for..This thing is just beautiful..
As for a siding replicator..If he did it..who knows what is ahead!!
There is many kit cars for the Shelby Cobra, VW kit cars...I was wondering what all it would take to replicate a old style brow face Winnebago..??
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 19, 2019, 10:07 AM
You have a CNC plasma cutter! I hate you!!! In the line of work I do restoring old military vehicles I would love to have one of those. I would say with your dedication to what you are doing and using the skins available through the outfit provided above you could make a new eyebrow. It would probably cost as much as buying a new modern coach but well worth it in the end.
I notice from all the clean and not rusty steel scraps under the plasma table and the fact that both it and the project are pretty much outdoors that you must be in the high desert area where it never rains and humidity is non existent.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 19, 2019, 10:25 AM
You have a CNC plasma cutter! I hate you!!! In the line of work I do restoring old military vehicles I would love to have one of those. I would say with your dedication to what you are doing and using the skins available through the outfit provided above you could make a new eyebrow. It would probably cost as much as buying a new modern coach but well worth it in the end.
I notice from all the clean and not rusty steel scraps under the plasma table and the fact that both it and the project are pretty much outdoors that you must be in the high desert area where it never rains and humidity is non existent.

I live right in the heart of California..Near Fresno..we get about 10-12 inches of rain and plenty of fog..So humidity is there to worry about..What you are seeing in regards to the scrap under the table is Galvanized..16 gauge cold rolled galvanized..It stays that pretty light gray and never rusts..During the cutting of the steel, you use simple compressed air..with air having 80% nitrogen in it..it nitrates (super hardens) the edge where it is cut..so the edge won't rust either..That is why it looks so new under there..

I knew someone like you would respond the way you did..that is why, the hideous laugh!!  BWA HA Ha!! (cough)..

Go take a good look at that cnczone website..there is a section for home built  plasma machines..Any questions you might have..let me know..I have been running that table since 2009..I can cut 20 gauge all the way up to 5/8..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 19, 2019, 10:33 AM
I usually don't go above 1/4 inch steel..Because anything heavier and I can't get it on the table..I don't have any kind of forklift or hoist..so experience of the thick steel is limited..Each type of steel has its settings..speed..voltage..gap distance between the steel and the torch..It is something that need to be set before you cut..I can cut 1/4 steel like scissors cut paper..It is simply awesome!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 19, 2019, 03:54 PM
I would become single if I told my wife I was going to get on more thing that make sparks!!! I have two stick welders, i MIG welder and a TIG welder. I also have two sets of oxy/acetylene torches, one full size and one compact. I do not have a plasma cutter and that is on the list of things to get. I might get interested in a table but I simply do not have any room. I work out of a single car garage and all my other stuff is in storage containers. I used to do a LOT of fabrication but with all the health issues in the last couple years I have had to back off. Cutting galvanized can be rather hazardous to your health, I am sure you know that.


And yea, I always look around the garage when someone posts pictures. Always looking for neat tools. You also get a feel for what kind of work that person does by their tools.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 21, 2019, 10:39 PM
So I am getting everything ready to lift out the lower section of the port wall..Working on the rear corner..This poor motorhome..The whole bottom edge is just gone..the whole circle around this thing..As I am opening up the corner..Just little pieces of wood keeps falling out..Now discovered the bottom apron on the back wall is totally rotted out..The more you dig the more you find..I can fix it..I have a plan
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 21, 2019, 10:46 PM
I took the rear door off..pretty much just being held there by the sealant around the edges..Someone had removed the trim piece earlier because it was being held with screws and the original staples were ground off..Then the bottom pretty much fell off..Just got to stay positive!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 22, 2019, 08:06 AM
I am assuming the bumper and all of that is welded on and that is why it is not being removed? Your dedication to this job is admirable, most of us would have reached for the matches by now.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 22, 2019, 08:49 PM
Hey Rick,
The receiver hitch is both bolted on and then welded to the front part of the bumper framework..So to get the bumper off, that weld will need to be cut..Then just unbolt everything from the frame rails..That panel on the rear just fell off when the trim piece was unscrewed..But to get the new wood in..The bumper has to be out of there..All I did today was get the rear axle up on stands and the rear tires off..Gets dark real soon now..I didn't get any pictures..Sorry
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Berlin-Tioga on October 23, 2019, 01:10 AM
We have a german saying/Sprichwort:


"Viel Feind, viel Ehr"


That's probably like: many foes, much honours  :D :)clap






Small tip for your glue-sliding problem: try some sugar grains between the parts. The don't interfere with the glue but reduce the sliding.




Keep on keepin' that dream alive!


Ben
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 23, 2019, 08:13 AM





Small tip for your glue-sliding problem: try some sugar grains between the parts. The don't interfere with the glue but reduce the sliding.




Keep on keepin' that dream alive!


Ben


Are you talking about regular food grade sugar? I never heard of that before, interesting. Learn something new every day.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 23, 2019, 09:36 PM
Okay here is some ripping going on..I cut that weld holding the bumper on..Unbolted it and needed a floor jack to lift and set it down after rolling it outward. What a heavy beast..
So with it out of the way, I could pivot the rear panel upward..Rot Rot Rot :'(
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 23, 2019, 09:40 PM
Here is another view of the panel..the second pic shows the strip of wood that secured the rear panel to the floor..There was about 3 screws actually doing any thing to secure this piece to the floor..What a mess..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 23, 2019, 09:46 PM
Here is the floor that secured the rear panel..This floor is a layered plywood..1/4-3/4-1/4 layers..Not a very good system..A piece of steel to screw to would be better..The original installation of screws just split all this open..Yea..More work to fix this..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 23, 2019, 10:02 PM
I decided to remove all this rot from the skin..Peeling the skin away from all that foam goes fairly easy..Just taking time to slowly peel it off without bending the skin..So now I have a full size template to recreate all this..sigh!! $@!#@! Thinking of just using a 3/4 plywood for the full area..Or make a frame work like it originally was..Like I said way earlier..There is nothing on this that isn't going to be replaced remade or redone on this..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: tmsnyder on October 24, 2019, 12:14 AM
I wonder if it would have been easier to take the whole thing apart completely, I suppose there was always hope that there wouldn't be rot everywhere you looked.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 25, 2019, 08:47 PM
"I wonder if it would have been easier to take the whole thing apart completely, I suppose there was always hope that there wouldn't be rot everywhere you looked"

That would have been easier..I always like doing things the hard way!! :)rotflmao
Here is the remake of the rear wall..and the scraps I have to work with to take measurement..I ran out of daylight and energy..Should be ready to try and fit this up tomorrow ..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 26, 2019, 08:24 PM
It is all framed up..A lot of work..But now there is wood where there use to be only foam..Wood to screw the taillights on...license plate..backup lights..Then glue and heavy stuff..After I set the frame on the ply with the glue, I just walked on it and that really settled the 2 layers together. Then a bunch of heavy stuff to hold it..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 26, 2019, 08:26 PM
I noticed this one one of the rims..This was an inner rim on the rear..The tire is holding air..Wonder what the problem is?? Maybe bent?? !-!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 27, 2019, 09:24 AM
Bent or maybe lug holes wallowed out? Or maybe marked as a bad tire from years before and never painted over? These are the things that you hate.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: tmsnyder on October 27, 2019, 07:56 PM
Maybe they were talking about the whole RV! :D
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 28, 2019, 12:01 AM
https://www.ebay.com/itm/Superflex-RV-Rubber-Roof-Kit-8-5-ft-Wide-Camper-Roof-Repair-30-ft/282406640117
I was looking around for a roof system EDPM  TPO ..what ever I could find and research..Saw this on Ebay..It is a little longer than I need but maybe he offers it at 25 feet..Just wondering what everyone thinks.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 28, 2019, 12:02 AM
Maybe they were talking about the whole RV! :D

Come on!! Be Nice!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 28, 2019, 08:47 AM
If you look down lower in that ad there are other size options, this one is 20 foot, https://www.ebay.com/itm/Superflex-RV-Rubber-Roof-Kit-8-5-ft-Wide-Roof-Repair-Camper-20-ft/272601663465?_trkparms=aid%3D555018%26algo%3DPL.SIM%26ao%3D1%26asc%3D60695%26meid%3D8be2e87d60fd4131ab279a958b263fa7%26pid%3D100005%26rk%3D1%26rkt%3D12%26mehot%3Dpf%26sd%3D282406640117%26itm%3D272601663465%26pmt%3D1%26noa%3D0%26pg%3D2047675&_trksid=p2047675.c100005.m1851 (https://www.ebay.com/itm/Superflex-RV-Rubber-Roof-Kit-8-5-ft-Wide-Roof-Repair-Camper-20-ft/272601663465?_trkparms=aid%3D555018%26algo%3DPL.SIM%26ao%3D1%26asc%3D60695%26meid%3D8be2e87d60fd4131ab279a958b263fa7%26pid%3D100005%26rk%3D1%26rkt%3D12%26mehot%3Dpf%26sd%3D282406640117%26itm%3D272601663465%26pmt%3D1%26noa%3D0%26pg%3D2047675&_trksid=p2047675.c100005.m1851).


I don't know anything about this stuff but if the companies he mentions are using it I would assume it is a good product since they certainly do not want issues with roof leaks on new units.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Berlin-Tioga on October 28, 2019, 04:21 PM
@ Rick
Yes, regular food grade sugar. The crystals reduce the sliding.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: TerryH on October 28, 2019, 06:14 PM
Great tip! Thank you very much.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 28, 2019, 08:31 PM
@ Rick
Yes, regular food grade sugar. The crystals reduce the sliding.

Not buying this story about sugar..It would act as small ball bearings..making it even more slippery during the laminating ..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 28, 2019, 08:38 PM
Sugar crystals are sharp edged, like salt but salt crystals are rectangular where sugar is multifaceted. Then again, it is processed sugar so I don't know. Have to get my magnifying glass out at morning coffee. Easiest way to find out is the next time you are gluing just try a small sample piece.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 28, 2019, 08:50 PM
sprinkle a little sugar on your kitchen counter top and set a dinner plate on top of the sugar..slippery!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ClydesdaleKevin on October 29, 2019, 08:13 AM
sprinkle a little sugar on your kitchen counter top and set a dinner plate on top of the sugar..slippery!!

It would still be something worth experimenting with.  The author of the suggestion is from Germany, and those Old World craftsmen might know a trick or two that we don't know about here across the pond.

Kev
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 29, 2019, 08:57 AM
What I am going to do next time on laminating a big piece like that is use dowel pins to locate the piece..First lay the 2 pieces together dry..no glue..Drill maybe 2 locations for a 1/4 inch dowel wood pins..Then they would act as locators for the exact position of the piece..Sort of like what is used on cylinder heads when you are reinstalling them on the block..Steel dowels that must drop into the holes on the block..Perfect positioning that way..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 30, 2019, 09:37 AM
A day without a post?! You are slacking off here Mike!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 30, 2019, 09:56 AM
Hey Rick,I got caught up in the world series..but I am working on it..Here is the rear panel frame work and I was trying a stain system for the wood..Went to Lowes and found some product to try out..I will be needing to figure out a wood color to stain all the new wood that will go into the walls..to finish them nice..Thought this piece would be a good test bed..This first can is some sort of primer to help the stain smooth out on raw wood..It was easy to apply..Sucked it in like a sponge.. 
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 30, 2019, 10:04 AM
And then used this stain..finish in one stuff..Way NOT dark enough..But that is one coat..maybe 2-3 coats or just get a darker color..This piece of plywood used here is only .2 of an inch thick..It was .125 originally to the coach..Finding that thickness 1/8 is hard to do..In essence is is door skin that you need..But here it isn't available..And 1/4 ply is not available..It is this 5 mm thick import wood..So I guess that is what I will be using to skin the ceiling and walls..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 30, 2019, 10:06 AM
I am going to try and fit this frame up today to complete the rebuilding of the back panel..I hope it all goes well..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 30, 2019, 01:08 PM
I love the look of real wood, all these people that paint the interiors................ Eh. You don't want to go to dark or you will have light issues inside, it will look like a cave. Unless you are into that. I personally like dark wood but not in a vehicle with little natural light. It gets gloomy after a while.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 30, 2019, 06:48 PM
Yes I know what you mean about paint..White..light turquoise or something..Reminds me of a hospital room!! I laid on another coat of stain.  This color is not gonna do it for me..Too Yellow..I need a medium brown..Go back to Lowes and see what other colors they have..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 30, 2019, 07:06 PM
That staining (second coat) was this morning..So this afternoon is was dry enough to handle and I tried a test fit install..Just using a floor jack..couple blocks of wood..slowly just jacked it up into position..At the top there is a lip of foam that interlocks with the wood..went right in..and everything else did well too!! :)clap :)clap :)clap I need to make new metal for the lower skirt of the wood..The side that faces forward and glue it on the stained wood..Then I think I am ready to install!! Drill some holes to run new screws into the flooring..I am going to run the screws where the flooring hasn't split open from the original install..Showed you that earlier..It is hard to show you with pics but it fits GREAT!!
Now for those of you with a good eye..Notice the lower cut out of the new panel..Those measurements of it show that it is centered ..The coach was made about 1/2 inch off center..I checked and rechecked..Its off..Oh Well!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: LJ-TJ on October 31, 2019, 05:43 AM
Said it before and I'll say it again. WOW! Great stuff. Your doing an amazing job and I'm sure are an inspiration to many of us out here. Showing us that yes maybe I we can do some of this stuff our selves. Thanks. Keep up the good work. :)ThmbUp
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: TerryH on October 31, 2019, 02:57 PM
Question for you Mike. Does your unit have those Type WDR AC electricity outlets - the very dangerous ones that connect by forcing the wiring onto V-blades that cut through the insulation to effect a connection. If so, are you upgrading them as you go?
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 31, 2019, 03:49 PM
I am replacing all the electrical..except the main fuse box..It seems to be in good shape..But here is a close up of an original plug..with the push in connector..Worst way you can do it but it passes residential code or they wouldn't be available..What happens with a circuit put together like this, especially a circuit with heavy use, such as being plugged into with a hair dryer (1500 watts ) or a space heater, is the connection gets fatigued, making resistance, making the plug itself get hot..
Using the screws on the side is much better because there is so much more contact with the wire..stronger with more surface area..But for a typical electrician, making a loop at the end of the wire and then having to loop it around the screw ..takes too much time..time is money and they want to make more of it..
I plan on replacing all the outlets and with as much as I am going to be reworking these walls, all the wiring too... I am so deep into the thing, I might as well!!
here is a little update on the back wall..New metal for the skirt below the floor line..The area that gets road grime thrown at it..Glued and screwed in place..
 
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 31, 2019, 05:58 PM
Those outlets are not the ones Terry was talking about, those there are fantastic compared to the blade type. I had those in my mobile home! The first time I had one fail and I got a look at it I went to the hardware store the next day and bought replacements for the entire place. They were all replaced within two days.


Here is one of those outlets, You just push the wires into those v notches as they pass by. The notches are visible in those center sections that bulge out to the sides. You can also see the plastic tabs that rotate out to grab the wall since they are not anchored to anything but paneling. Now think about that with all of the movement in an RV!


https://encrypted-tbn1.gstatic.com/shopping?q=tbn:ANd9GcQiZTSMcp-ErON9qpMgB2AV6aPhr1uaG1CgwH39xk9Fl2x_uCIU1lA4fOF3U4r_lYtHn-gYD4xr7fQfun0BGuhW-naRmamQdA&usqp=CAY
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on October 31, 2019, 05:59 PM
Mike, Do you have aluminum wire in there? If so either replace it (best idea) or make sure you get outlets rated for aluminum wiring. Otherwise the connections WILL come loose.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: TerryH on October 31, 2019, 06:19 PM
Those outlets are not the ones Terry was talking about, those there are fantastic compared to the blade type. I had those in my mobile home! The first time I had one fail and I got a look at it I went to the hardware store the next day and bought replacements for the entire place. They were all replaced within two days.


Here is one of those outlets, You just push the wires into those v notches as they pass by. The notches are visible in those center sections that bulge out to the sides. You can also see the plastic tabs that rotate out to grab the wall since they are not anchored to anything but paneling. Now think about that with all of the movement in an RV!


https://encrypted-tbn1.gstatic.com/shopping?q=tbn:ANd9GcQiZTSMcp-ErON9qpMgB2AV6aPhr1uaG1CgwH39xk9Fl2x_uCIU1lA4fOF3U4r_lYtHn-gYD4xr7fQfun0BGuhW-naRmamQdA&usqp=CAY

The Type WDR were dangerous enough when originally installed, but if removed and reinstalled the danger was highly compounded.
An electrical fire is difficult to completely extinguish and often reignites, sometimes an hour later.
I know of two boats that were destroyed that way.
Anyone with these should seriously consider replacing them. It is not difficult, other than those - such as galley outlets - that are installed in an exterior wall.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 31, 2019, 06:45 PM
Mike, Do you have aluminum wire in there?
No aluminum wiring..All of it copper..but I have to replace it all because of the rework of the walls..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 31, 2019, 09:04 PM
I was going to mount the rear wall this afternoon, but this brought me to a screeching halt..This is just below the plywood ..below the storage area in the rear..The grounding lugs for the 12 and 110 volt systems..All rusted and loose..When the back wall is on, there is about 2 inches of space to service this thing..Now is the time to fix it while it is all open like this..So why not get something new and install it inside the storage area..Where it is nice and dry and doesn't have road mud and salt thrown all over it..Run a bolt straight down through the plywood and that 2x2 steel floor support piece..Nice and tight and accessible..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 31, 2019, 09:07 PM
Then I found these special screws that will be perfect for mounting the wall back on..With a special head that is flat to keep from splitting the wood like a bugle head screw can do..All of this was at Home Depot
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 31, 2019, 09:37 PM
https://www.ebay.com/itm/White-Self-Contained-Outlet-Receptacle-Snap-Plug-w-Plate-WDR-Mobile-Home-Camper-/153319102873 (https://www.ebay.com/itm/White-Self-Contained-Outlet-Receptacle-Snap-Plug-w-Plate-WDR-Mobile-Home-Camper-/153319102873)
Looks like that plug can still be bought even with the stories of them being so bad..I have never seen this type of plug..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: yellowrecve on October 31, 2019, 09:39 PM
You can not get a good ground going through wood and steel. The bolt will lose it's tightness because of the give in the wood. Find a spot clamping only metal or weld a tab onto a frame member. Your doing a nice job.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on October 31, 2019, 09:48 PM
https://www.youtube.com/watch?v=Tuo2EFKfJ58
A video on installing those plugs..That looks like an instant fire hazard

quote author=yellowrecve link=topic=15119.msg94573#msg94573 date=1572575988]
You can not get a good ground going through wood and steel. The bolt will lose it's tightness because of the give in the wood. Find a spot clamping only metal or weld a tab onto a frame member. Your doing a nice job.

Yes I didn't even think of that with the wood..I sure would like to get it out of the area that you can't even reach into..needs to be solid mounted
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ClydesdaleKevin on November 01, 2019, 07:24 AM
https://www.youtube.com/watch?v=Tuo2EFKfJ58
A video on installing those plugs..That looks like an instant fire hazard

quote author=yellowrecve link=topic=15119.msg94573#msg94573 date=1572575988]
You can not get a good ground going through wood and steel. The bolt will lose it's tightness because of the give in the wood. Find a spot clamping only metal or weld a tab onto a frame member. Your doing a nice job.

Yes I didn't even think of that with the wood..I sure would like to get it out of the area that you can't even reach into..needs to be solid mounted


You could bring the bolts down through the wood and then down through the 2x2 steel...and then weld the bolt head to the 2x2.  Problem solved, permanently.

Kev
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Elandan2 on November 01, 2019, 07:27 AM
You could use a bushing through the floor for the bolts to go through. That way the grounds would still be inside, but effectively bolted directly to the steel frame.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 01, 2019, 08:10 PM
Everyone with a good idea on how to do this..This is what I came up with..And it had to do with what I had laying around here in regards to steel and stuff..1/4 inch plate..Holes drilled to mount the ground bar..5/16 bolts and locking nuts..Cut a slot in the wood to let it drop down to the frame floor support..Clean it all up and weld it!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 01, 2019, 08:15 PM
STOP IT!! Don't laugh!! I am not a welder and never played one on TV :-[ ..I got the penetration of the steel but it is far from pretty..STOP LAUGHING!! :)rotflmao ..It worked and it is a lot better than what was being used for sure..And you can check on it to be sure all is tight with the wires
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 01, 2019, 08:17 PM
Now where was I before I was so rudely interrupted with this ground bar..Oh Yea!! The back wall...Tomorrow
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: LJ-TJ on November 01, 2019, 10:06 PM
 :)rotflmao  Where not laughing at you. Were laughing with you. Cause that looks like about what the rest of us do. Looks pretty good to me. As we all know it's all about the penetration. D:oH! Did I just say that.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on November 02, 2019, 04:58 PM
The welding um, err, welllll, ................................................... Kinda needs a little practice. W% W% :D
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: tmsnyder on November 02, 2019, 07:38 PM
We know you did it for originality's sake.  I believe Rick has noted that the Winnie's had some pretty poor welds on the frame extensions.


Someone's going to find that in 50 years and say 'this must be an original weld!'
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: tmsnyder on November 02, 2019, 07:50 PM
:)rotflmao  Where not laughing at you. Were laughing with you. Cause that looks like about what the rest of us do. Looks pretty good to me. As we all know it's all about the penetration. D:oH! Did I just say that.


Equipment helps too.   Anyone ever stick weld with a Lincoln IdealArc 250?   The old round-top one?   I saw one at an estate sale and remembered my dad said he always wanted one.   He always had the AC-225 buzz box when I was growing up.  The difference is about 300lb, there's a lift hook on the top of the IdealArc.  Anyway, I called him and asked him if he wanted it and he said 'try it out and if it works buy it'.   I went in the garage and threw a piece of scrap steel on the table, pulled a stick out of a decrepit looking can, guessed at a setting, struck the tip of the rod on the piece and was greeted by the smoothest sounding arc laying down the most beautiful weld I think I ever did.   I bought the welder and about 100 lb of 7011 rod in sealed tins for $100.   The hardest part was telling my dad I was keeping it for a little while.   I eventually gave it to him a year or so later after I used it to repair my buddy's dump trailer which was a basket case, for his wedding present. 


Another year went by and I was talking to dad and he was telling about welding something up with the AC-225, I said why not the IdealArc, and he said oh-yeah, I should try that.  Next day he said 'holy cow, that's some welder! should have been using that all along!'


Long story short, you can weld with some welders (HF for instance) but all welders are not made equal, it can make a big difference.   Some just put a smile on your face!



Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 02, 2019, 07:57 PM
I just came in with the camera..Bunch of pictures to show..Originally the coach didn't have anything holding the corners together on this back wall..Can't because all there was foam down the length of the corner..So the only thing holding it together was the wrapping of the aluminum skin over each other and staples into the 1x2 that was there..I will be fixing that..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 02, 2019, 08:06 PM
I think those welders were called tombstone welder..looking like something in a cemetery..I have only used (barely) a Mig welder for anything I have ever done..But it really doesn't matter as it (that weld) is covered up with my FRESHLY INSTALLED WALL!!!!!!!!!!.. Just glued the top edge and slid it right up to fit with the foam that is at the top of the curve..Those screws with the big flat head worked Great!!..This wall is like a block concrete house!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 02, 2019, 08:13 PM
Used a couple of 2x3 to clamp the glue down to the skin..Clamps and a screw at each end held it tight..Reach up and add more glue and another 2x3..Just slowly iron it down..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 02, 2019, 08:25 PM
I think I am done with the remnants of the old wall..I cut it up and currently it is burning in my fireplace!! :)clap
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on November 03, 2019, 09:30 AM
Mike, I was just busting on you about the weld. You did not exactly have optimum conditions there and you had said before you were not a welder. If it were structural I would have ranted but this was fine for what you needed. I have not really said anything up to now about weight but this thing is going to be heavy! It will definitely be solid!! But you are going to want to put it on the scales and see where it is once you are done so you know if you need to make suspension upgrades. The GVWR was pretty much a farce on any RV and especially when slide in campers were involved since they all lied on the weights. Any of these were overweight as soon as you filled the water tank and installed the occupants. You just want to be sure that you are safe that's all. I guarantee that it will not fall apart in a crash like the originals did!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on November 03, 2019, 09:37 AM

Equipment helps too.   Anyone ever stick weld with a Lincoln IdealArc 250?   The old round-top one?   I saw one at an estate sale and remembered my dad said he always wanted one.   He always had the AC-225 buzz box when I was growing up.  The difference is about 300lb, there's a lift hook on the top of the IdealArc.  Anyway, I called him and asked him if he wanted it and he said 'try it out and if it works buy it'.   I went in the garage and threw a piece of scrap steel on the table, pulled a stick out of a decrepit looking can, guessed at a setting, struck the tip of the rod on the piece and was greeted by the smoothest sounding arc laying down the most beautiful weld I think I ever did.   I bought the welder and about 100 lb of 7011 rod in sealed tins for $100.   The hardest part was telling my dad I was keeping it for a little while.   I eventually gave it to him a year or so later after I used it to repair my buddy's dump trailer which was a basket case, for his wedding present. 


Another year went by and I was talking to dad and he was telling about welding something up with the AC-225, I said why not the IdealArc, and he said oh-yeah, I should try that.  Next day he said 'holy cow, that's some welder! should have been using that all along!'


Long story short, you can weld with some welders (HF for instance) but all welders are not made equal, it can make a big difference.   Some just put a smile on your face!


And if you see one of those tombstone welders and you want to buy it be SURE it is one of the OLD ones and not the newer ones from Home Depot and such. World of difference in weld quality. The old ones weight about 150-200 lbs. the new ones are half that much. That weight difference is in the transformer and means a lot more stable and consistent arc.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 03, 2019, 01:01 PM
I have not really said anything up to now about weight but this thing is going to be heavy! It will definitely be solid!! But you are going to want to put it on the scales and see where it is once you are done so you know if you need to make suspension upgrades. The GVWR was pretty much a farce on any RV and especially when slide in campers were involved since they all lied on the weights.
I really don't think I have added that much weight to this..I think that I am about even..First there was 2 36 gallon water tanks on it at about 55 pounds each..Being replaced with a new plastic tank...There was 2 layers of carpet..gone..I was thinking of vinyl for the floors..There was these asbestos tiles laid in the rear area..Heavy!!  As for the roof, I showed that the original was only  a little lighter than the roof I installed..That original  roof was a failure when it was brand new..Making it flat like that with a 250 pound AC up there..It sagged from the beginning..Screwing things together in to foam was silly..No wonder it rotted so fast..Corners and structural integrity being relied upon with foam ...Really??..Yes I have added wood where there wasn't any before..But I don't think I am loading it down..Off sets from weight saving in other places 
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: LJ-TJ on November 03, 2019, 01:21 PM
Hey Mr to a certain degree I did the same thing as your doing back in the day. You doing :)ThmbUp  it bag on and I would change a thing. Keep it up.. Your doing fantastic. I have to check in a few times a day to be sure I don't miss anything. Thanks for taking the time to post. Especially with a project this size.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on November 03, 2019, 06:32 PM
I would do it exactly the same way as you (if I had the smarts working with wood that you do). Just pointing out it would be a good idea to scale it when done.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 05, 2019, 09:04 PM
Time for the starboard wall lower half to come off..The aluminum trim piece that goes on the bottom of the skirt is missing..Thus all the wood confetti fell out on the road..So there wasn't the usual amount of wood scrap falling on the ground..I stilt the ceiling up with 2x3s and pocket hole screws to keep them in place..With the change of daylight saving time and the days just getting shorter, it might take longer to get things done..I will try to drop the wall off tomorrow
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 05, 2019, 10:56 PM
Just click on this link in picture 1 and then scroll down to this section on selling things..I wish you weren't so far away!!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 08, 2019, 08:51 PM
After breaking the glue line open..the seam..it pretty much just slipped off the joint and set on the sawhorses..Thing weighs about 60-70 pounds
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 08, 2019, 08:54 PM
Here it is on the ground..I will set up some moving blankets on the concrete and lay it on those..Then start rebuilding!!
Don't worry people..I have this way under control.. ???
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: LJ-TJ on November 08, 2019, 09:27 PM
 D:oH! :)rotflmao :)rotflmao :)rotflmao :)clap Your Nuts ;)  Your doing a great job.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on November 08, 2019, 10:14 PM
Are you doing this by yourself?
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 08, 2019, 10:22 PM
Yep!!..No wife to help..divorced..No kids..never had any...So for all of you who think this project is too hard..Try doing it alone!! It is not that hard..Just think it through on every step..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on November 09, 2019, 08:54 AM
I know how you feel, most of what I do is by myself since my wife is unable to help for the most part and I am the type that if it needs to be done I am going to do it no matter what. As my disabilities mount I have to admit it is getting harder for the brain to admit that the body is just not 25 years old anymore. D:oH!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: tmsnyder on November 09, 2019, 10:03 AM
Reminds me of my cousin's house, he kept finding rot and replacing walls until all that was left of the original house was the foundation.  But when you're in the middle of it there's no way to know where you're going to end up.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 09, 2019, 07:05 PM
Hey Rick, Is that any better?? :)clap Been watching welding you tube videos..weldingtipsandtricks is a channel to learn from!!  Next I am going to remove my own appendix from my side..There is a vid on that and it looks easy :)rotflmao
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on November 10, 2019, 09:38 AM
Excellent!!! Other than a tiny bit of mill scale inclusion which is negligible there is nothing at all wrong with that weld. Weldingtipandtricks is an excellent site for welding videos. Weld.com is another.
Curious about your welder, I have the 180C which is the commercial version. The retail version the dials click into each position and the commercial version the dials are smooth and infinite. I never saw a "dual" version. Naturally when I need a picture of mine I can't find it.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: LJ-TJ on November 10, 2019, 10:44 AM
Ok! Boys, Not to stray to far from the subject. For several months I've been trying to decide on a welder 220. I narrowed it down to the lincoln 180 mig. But there's to many. An opinion would be appreciated. For Farm use as well as Winnie us. Hm? 
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 10, 2019, 12:04 PM
Just to help with the decision, here is some detail shots of the welder..It comes with 2 cords..each with it's plug to switch it from either voltage ..Just twist and lock the cord to the back of the unit..Comes with a spool of .025 mig wire..Still using it, which shows how little I have used it..And a spool of flux wire..035...The gas regulator..and all the accessory pieces to switch wire gauges at the wire feed..wheels, guide etc.
Looking at the setting chart, it really doesn't add to the max thickness of steel that you can weld..going to 220 just speeds the process up in comparison to the 120..I bought it at the professional welding shop that supplies businesses with gas and tanks..A place that does nothing but welding..Not Home depot or Lowes
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on November 10, 2019, 03:29 PM
Do the dials rotate smoothly or do they click into each position? Like position A, B, C, etc or just wherever you leave it? The latter choice is the proffesional model that I have and now I see what the dual means, 110 or 220. With 220 you get a much more stable arc.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on November 10, 2019, 03:40 PM
The difference between 110 and 220 mainly comes down to the amperage available to you. You are going to be limited to around 90 amps on 110 volts. Welding voltage is around 21-27 volts, which is a quarter of the 110 volts coming in. so 90 amps out divided by 4 equals 22.5 amps input at 110 volts. You are probably going to pop a breaker unless it is a 25-30 amp circuit. Where at 220 volts the same 90 amp output is a multiple of 8 so the amperage drawn from the outlet is 11.25. 180 amp maximum power will draw roughly 22.11 amps. 180 amps on 110 volts will draw 45 amps from the outlet!!


Hey TJ, So you wanna be a welder huh, well here you go. 1000 amp stick welding


https://www.youtube.com/watch?v=j61ezBX-EyA (https://www.youtube.com/watch?v=j61ezBX-EyA)
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 10, 2019, 04:15 PM
Did you notice on the video, that the first guy with the long beard showed his welding..After cleaning the slag..But the other guys didn't show their work Hm? ..Did anyone learn anything on this??  How to act silly and make money on you tube doing it!! :)rotflmao My welder does not have detentes..rotates smoothly..I ran that bead earlier using the 110 plug on a dedicated 20 amp circuit with the dials shown at their positions..Didn't pop the breaker..with a 50 foot 10AWG extension cord ..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: LJ-TJ on November 10, 2019, 05:43 PM
Well thanks lads. Like I said I didn't want to change the direction of the threat. Appreciate the comments. Looks like that's the route I'll go. No Rick I wouldn't insult real welder by thinking I'm a welder. D:oH! :)rotflmao
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 10, 2019, 08:27 PM
Working on the wall this afternoon..I just cleaned it up and set it up for the rim joist piece ..the 2x4 that gets screwed into the floor..pressure treated ..You just line up the lower aluminum piece to the upper..lining up the original screw and staple holes..Hold in place with a little tape to keep it from shifting then glue up the 2x4 with plenty of liquid nails..Weigh it down  give it about 2 days to harden up, then start building the skirt frame work..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on November 16, 2019, 08:35 AM
Did you notice on the video, that the first guy with the long beard showed his welding..After cleaning the slag..But the other guys didn't show their work Hm? ..Did anyone learn anything on this??  How to act silly and make money on you tube doing it!! :)rotflmao My welder does not have detentes..rotates smoothly..I ran that bead earlier using the 110 plug on a dedicated 20 amp circuit with the dials shown at their positions..Didn't pop the breaker..with a 50 foot 10AWG extension cord ..
Did they go to an inverter style setup? If so it will automatically regulate the output based on the input but even then that is a good looking weld for 110 volts. The true test would be to check the penetration.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on November 16, 2019, 08:40 AM
Come on now, A week with no progress! We are going into withdrawal here.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: LJ-TJ on November 16, 2019, 09:10 AM
Oh! This is painful. However perfection takes a little longer. Withdrawal! That's an understatment.  It's like going to a Saturday Matina and following a Buck Rodgers cerial and finding  out it will be a month before the next sequal filmed.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 16, 2019, 12:04 PM
Oh Man!! I am so sorry about this..I sold the thing!!..Got an offer that I couldn't refuse!!!!......................NOOOO!! Just Kidding :)rotflmao ..It is the problem with the time change and getting dark at 5pm..I am able to get some work in on it at the end of the day then it is too late to take good pictures..I just took these this morning and I will be doing more this afternoon..
Finished the lower skirt area..not completely..couple of little details but in essence it is done..Now needs to have the top 1/4 ply on top of that..Got some 20 gauge galvanized..Little lighter than the 16 that I used on the front area of the wall....So that needs to be put on..I will just use tin snips to shape all that..Not the plasma (BWA HA Ha) cutter..This all might look like the wall of a Brinks armored truck but it really hasn't added that much weight to it..every piece of wood is there for a reason..Mostly to secure it to the steel framework of the chassis..That frame work around that door hatch opening..It leaked there  before because the screws were secured only with the 24 gauge aluminum that the screws went into..Now there is actual wood!! Imagine that..Screws into wood..what a concept!! Here are some pics
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 24, 2019, 08:24 PM
I am BACK!!!I am doing the best that I can but it gets dark so early now..But this is what I was able to get done today..The plywood along the edge was really sagging..Added some reinforcement..
Did the best I could on the welding..function over form!!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 24, 2019, 08:28 PM
And then this tire blow out mess..Right rear mud guard area..The wall is ready to be installed..Just need to fix the details first..while it is easy..The propane lines need to be fixed too..Do a little bit of modifying on that...
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on November 24, 2019, 08:44 PM
The one weld on the angle looks perfect and the other looks too cold or you had the gas off, really looks like the gas was off, or the wind was blowing. You can't mig weld in the wind. On the fender it looks like you need more heat. Function over form only works when the function holds!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: LJ-TJ on November 24, 2019, 08:55 PM
 :)rotflmao :)rotflmao :)rotflmao :)rotflmao  I new you'd catch that Rick. Hey Mike your doing a fantastic job. :)clap Keep up the good work. I'm thinking there's a lot of us look forword to checking in every week now to see how your doing.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on November 25, 2019, 08:40 AM
I wouldn't have said anything if Mike didn't but since he did it seemed he was kind of frustrated with his results so I figured I would offer what I saw.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on November 25, 2019, 11:38 AM
Here is a couple of better shots of the 2 welds made on that floor reinforcement Up close and personal..Watching videos on vertical mig and upside down mig, even these professional welders struggle with upside down stuff..Vertical is made going uphill..gun pointed uphill..that worked pretty good for me..but to get into position to make any kind of upside down weld involved being on hand and knees to support yourself..then trying to get it in there without it raining down molten steel on your hands and arms..For what I was working with and the limited skills that I have, I don't think that weld will be going any where soon..On the next attempt, I will open up the argon CO2 mix for a higher flow..That might work..
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: LJ-TJ on November 25, 2019, 12:46 PM
I smile only because anybody who has welded and had to weld up hill has run into the very same experiance. And yep! our welds looked about like that. Hehehehe
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Rickf1985 on November 25, 2019, 06:11 PM
I have had plenty of those welds. you need to turn up the heat and move fast. So you are running higher heat, faster wire and moving faster so that it cools before it has a chance to drop out. If you thin it is hard with MIG try it with stick! With stick I would be using 6010 or 6011 since it is a fast setting rod but it is also deep penetration so you always have a compromise.
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Gearhead88 on December 01, 2019, 01:41 PM

Wow !!!


I just read this entire build thread . You are one determined  and ambitious guy !!




You have some skills !!   :)ThmbUp
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ClydesdaleKevin on December 21, 2019, 10:48 AM
Any more progress on this Mike?  It has been a while!


And Merry Christmas!!!


Kev
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: RockwoodMike on December 21, 2019, 11:27 AM
Hi Kevin,
I am afraid not..With it getting dark at 4:30 during the winter..I use to be able to work a couple of hours on it after work during the summer..Not right now though..
I have it all covered up..just waiting out the winter weather..
The next thing that I am going to do is drop out the fuel tanks..See what is all with that..There was a fuel delivery problem when I brought it home..with the side open as it is right now, getting to the tanks will be much easier..Then I will put that side back on..
So that is about it..Just hurry up and wait out the winter..
Merry Christmas to you too!!
Mike
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: LJ-TJ on December 21, 2019, 02:06 PM
Back atcha. Was wondering how things were going. Any way hope you all have a Merry Christmas and all the best to you in the New Year. Maybe Santa Clause will bring you some good stuff. :)clap
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: ralis on April 30, 2021, 06:57 PM
I happen to own a CNC Plasma steel cutter..BWAAA HAAA HAAA coff coff coff weeze :)rotflmao Got all the info on how all of these type of machines work from cnczone dot com and decided to build one for myself!!
I needed to make a new skin for the inside of the fender well..Instead of the original aluminum, this is 16 gauge galvanized cold roll steel..Heavier but lots more durable for all that happens in the wheel well..

um hi! I need one of those!
Title: Re: Mike's 1973 D22 Complete tear out. From the Roof down!
Post by: Oz on May 01, 2021, 09:29 AM
Don't we all!   :)