It's a crappy job but...(pun intended)

So even though we aren't going to have a potty we still need a place for the grey water(sink) to drain to. I read about someone else on the VSTF cutting their original tank and repairing it with a 3M Fiberglass repair kit, so that's what I did.

Here is the original tank that the original toilet and sink drained to, the thing was massive and nasty. Imagine a 50 year old tank whose only job was to collect filth. But I survived, and saved myself a lot of money. 

Tank cut to the new size, once again I used my Festool Trion Jigsaw, also if you do this wear a respirator, fiberglass is nasty stuff to breath and guess what else is in that tank.

I cut the end cap off the piece of the tank that I was not going to use to make up the other end. What you don't see is me scrubbing the inside and soaking the tank in a 50/50 bleach/water solution. 

Tank glued and patched back together, notice the notch, this is so it fits around my built-in nightstand. I am doing a leak test in this picture, the new tank holds 10.5 gallons. I also replaced the drain on the bottom. 

When Pigs Fly, or Canned Hams

This is a tutorial on how to rebuild your original Shasta wings, I only recommend doing this if you have the original edge trim, otherwise I recommend buying them.

I had one complete wing and one missing its core, the original cores had long since been rotted and actually shrunk, so using them as a template was not going to work. I used the original skins as a pattern.

ROT, ROT, ROT!

I chose to use Western Red Cedar, its light and fairly rot resistant. Some people use PVC boards but I am not one to reinvent the wheel or the wing, after all the original Douglas Fir lasted for 50 years!

After you make your cores you will need the following tools

1) Shears

2) Sharpie Marker

3) Leather Gloves

4)Tape Measure

5) Combination Square

6) Pizza Cutter

7) 4ft Level or Straight Edge

8) Blanket

9) 0000 Steel Wool(not pictured)

10) Windex(not pictured)

From this point on wear gloves! I used 26 gauge Aluminum, it was the left over from my roof.

I traced the wing core on to the Aluminum

Using the hand shears I carefully cut the pattern out. TIP: Don't close the shears all the way, if you stop about a 1/4" before the shears close you will get a clean cut and avoid little pinch dents.

I used the Combination Square and Straight Edge to transfer the score pattern from the original to the new blanks. Then put the blanks on the blanket, use the pizza cutter and straight edge to score the aluminum. I did three passes on each line applying moderate pressure.

Use the 0000 steel wool and windex to buff off the marker lines, make sure to go front to back, and not up and down or swirl.

Assemble, make sure to use Stainless Steel Screws. Patience is needed when installing the skins and edge trim. Predrill all screw holes

Install using #10 Stainless Steel Screws 8x 1 1/2" and 1x 1 1/4" used at the tail.

I can see the light

The Trailer inches closer everyday. I have all the window and the missing glass installed. I only have to install the main door and in its winter ready.

I also installed the Fantastik-Fan, I chose the gray trim since it looked the most like the original aluminum silver.

Give Me Some Skin!

Its been a long month and a half since I last updated this, I have been very busy with a basement remodel job, and the things I've done on the Shasta have not been blog worthy! 

Lower front skin and the small panels that go on each side of the window are done. The back is also done but I am not really happy with the results so I am not showing it! I have absolutely no metal working experience and the back has some ripples.

My new one piece roof, it came to me in a roll 8.5' wide by 16' long. It's not really that heavy just awkward and sharp!  One piece roofs are far superior than the old 4 piece roofs and believe it or not they're cheaper too!

The problem is the Shasta is only 7' wide, so how do you get a clean straight cut? A really good jig saw and a new blade. I have made all my cuts, windows, doors, the curved roof line and now trimming the roof to width using a Festool Trion Jigsaw.

One of my favorite pictures, the roof is like a mirror! 

So the issue with the one piece roof is how do you get a water tight seam? I used a Folding tool that is made for making HVAC vents, I folded a 1" flap in the skin and than a 1"flap in the roof and locked them together, basically making a "S" lock seam.

Not really the funnest part of the build, folding over the roof and nailing it. 

All done and the front window is finally installed!

So Close!

Well I missed my goal of getting the new skin on before it snowed as it is currently snowing...So close!

The trailer was final prepared for the skins as I sprayed the bottom with a rubberized coating to seal the wood and protect it. I also sealed all the light wiring.

The newly fabricated skin panels! This is 1/2 of one side, its 4ft wide x 13.5ft long, and very flexible.

This is the front panel the back is under it!

Thank goodness for cabinet jacks and our wood fence, it really helped fitting the first panel.

I racked my brain on how to cut out the windows and the shape of the trailer itself, Found that a jigsaw with a metal blade worked the best.

While waiting for UPS to show up with some Stainless Steel nails so I could fasten down the bottom of the upper panel I installed the grab handle and front marker lights.

Nails showed up about 4:30, it was go time! I only had about one and half hours of daylight left and we were suppose to get a cold front overnight(we did)!

One side Done! 

The Devil is in the Details

The Kitchen is taking shape, all the sink and appliances are now refinished and installed!

The backsplash is finally in, note aluminum trim and the retro aluminum cove molding. Even the chrome nails are true to the original Shasta method of installing the backsplash.

I redid the counter top edges with a retro 50's style wavy aluminum that looks more period.

Knock Knock....

I was able to knock(no pun intended) a few little items this week, including a new door, finishing my newly built Magazine rack, and installing new copper gas lines.

The old rotted and warped door.

Newly minted door

All Shellac'd and insulated and was able to find a NOS(New Old Stock) Bargman L-66 door handle, a knob that hasn't been manufactured for a least 30 years.

One of our favorite details of Shasta trailers was the magazine rack with the big "S"! I built a new one true to  every detail of the original