chris
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1958 Shasta Airflyte
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Post by chris on May 24, 2016 1:24:38 GMT -8
Hey, everyone! A few folks asked for specifics and pictures of my 1958 Alaskan Shasta. I was out of town for a bit, but I'm back and happy to share where I'm at and what ideas are guiding the "spruce up" (not a restoration) of the Shasta.
Here's how I found it in a little place called Sourdough, AK. I bought it from an old friend of my wife's grandparents who had a cabin close by. I don't have any pictures of the camper in it's original setting, because they hauled it up the hill (about 100 yards) to the grandparents cabin before I could get a camera. But these definitely reflect the condition of the camper... Along the bottoms of each side (near the front) you can see some steel flat bar stock that was added presumably to stiffen up that area. I actually wasn't sure if that was stock or not, but I definitely don't see it in any other old Shasta pictures.
You can see how the roof got smashed in at some point from the snow. This damage obviously transferred to the inside as well.
There were some modifications done to the front at the bottom. It appears both front corners got a little crunched somewhere along the way. Besides the added heavy gauge aluminum, they also added a 6x8 timber on the inside along the front bottom corner. The timber is the one piece of Alaskan engineering I think I'll keep. It might add 30 pounds to the weight, but it really gives you something substantial to attach everything to at the front. Structurally, I like it.
In the interior, the back was definitely the worst. The ceiling was split due to the roof collapse. The contact paper on the back wall was covering the parts where the plywood was completely delaminated and-in some cases-gone from all the water damage. There were many seams (not just the back window) that were leaking. Underneath the home-made bed, both back corners were completely rotted out.
The front didn't look nearly as bad as the back, but the cushions and table were covering a lot of water damage from the leaking windows. After I removed the skin, I could see that edges of the front plywood were delaminated and splintered off, so there was nothing really attaching it to the sides of the camper.
So all-in-all, not a complete write-off, but I probably would have walked away had I realized how much damage I was going to find. There were just tubes of silicon squeezed into every nook and cranny of this camper. With less-than-overwhelming support from my wife, I started taking pieces off just to find more rotted wood. Eventually, I discovered (as all of you already know) that you can't replace the ceiling or the back wall without taking the aluminum top of the camper. You can't replace the rotted wood in the back without taking the aluminum sides off the camper. With every piece that came off, her hopes of camping by June were becoming slimmer and slimmer. Eventually, it was deskinned, the back/top/front plywood was taken out, and I started replacing the bad wood. This was the camper at it's lowest point... (Although you can see I had already started replacing some of the wood.)
So, the dream of June camping is still alive (barely). Before the pictures of where it sits now, I have to share my philosophy of "sprucing up". I know some of you won't agree. My personal desire would have been to rip this whole thing off the frame, sandblast, recoat, and start assembling piece-by-piece, restoring as I went... But in the end, that's not what we want. We (my wife and I) have kids that aren't getting any younger. As much as I LOVE bringing old stuff back to life, we don't want a perfectly restored camper that we're afraid the kids might scratch up. We want a camper they can enjoy. 20 years from now, I doubt they'll look back and say, "Man, my dad did a really nice job of refinishing those cabinet faces." And if I spend the next year restoring it, that's one less summer we're camping in it. We don't mind that the 58 year old cabinets have nicks and scratches. That's the character that comes from 58 years of having a good time with it. That being said, it must be safe and structurally sound, so I made sure it is. Obviously if I'm replacing plywood on the inside, I'm going to try to make it look nice. But when you see nice, new ceilings with old, beat up cabinets, and laminate floor instead of original-looking black-and-white vinyl tiles, you'll know where I'm coming from.
Here's where she sits right now...
The back before I put the floor in. I can't get enough of that birch grain with the amber shellac! Question for the masses: I took the old homemade bed out and I would like to build something more like the original convertible couch/bed. Does anyone have some good pictures of one. I don't necessarily need detailed plans. Just an overview of what the framing looked like when it was in and out. Thanks!
You may notice my back hammock bracket is broken. Anyone know where I can get an original?
View of the whole camper from the front window.
From the rear window. You can see that timber along the front I was telling you about.
The front area. No, these are definitely not original benches, and yes I would actually like to replace them with a something that looks a little less homemade, but they're fine for now. I'll make new ones once winter rolls back around.
Finally, the outside is ALMOST ready to reskin. You can see how much wood got replaced. Basically all along the bottom and a lot of the corners. A little bit to tidy up right up front at the bottom and I need to put on the wood strips around the edge for the aluminum and then the new skin goes on...
If you made it this far, I'm impressed and thanks for reading. I'll definitely post a few more once the skin goes on and it's painted. If anyone can pass some pictures of the bed or knows where to get an original hammock bracket, I would be much obliged.
Cheers! Chris
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Post by Ross on May 24, 2016 2:53:08 GMT -8
Beautifully done, so far, Chris!
North Pole is an awesome place. First time we saw reindeer. My 2 daughters and I would go visit my aunt and uncle, at the time and they lived in Fairbanks. We would use their place as home base and do some traveling around. Did some tent camping while we were there during July, if I remember and we knew right then why the skeeter is Alaska's State bird....he-he-he
As for canvas bunk brackets, they pop up on eBay from time to time. Do a search for Scotty camper, Shasta camper, vintage camper or vintage trailer. These are the typical tag words to find those brackets.
Keep up the great work and keep the pictures coming.
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nccamper
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1962 Forester- 1956 Shasta
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Post by nccamper on May 24, 2016 4:14:30 GMT -8
The woodwork looks beautiful.
"If anyone can pass some pictures of the bed or knows where to get an original hammock bracket, I would be much obliged."
Trailertrasher recycles vintage camper parts. Send him a PM asking about the brackets.
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turbodaddy
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17' 1965 Fan "Sunseeker"
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Post by turbodaddy on May 24, 2016 6:52:55 GMT -8
Very nice!
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Post by vintagebruce on May 24, 2016 7:59:46 GMT -8
Great job so far. I lived in Valdez for five and a half years, so I know what snow loads can do to exposed campers. It sure is great to see this Shasta being saved. If you should run into a dead end for the bracket, I have seen some campers that have a horizontal strip of wood with just slightly larger than your hammock pole diameter cut-outs into the top edge, tied into your framing, and stained to match your interior. If you just need one, a Member may have an extra one to offer you. Keep up the good work! Here is another option that SusieQ found. vintagetrailertalk.freeforums.net/thread/1045/canvas-bunk-brackets-new-cheap
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Post by vikx on May 24, 2016 20:58:39 GMT -8
Wow! Looks great Chris.
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mtpalms
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Post by mtpalms on May 24, 2016 21:23:10 GMT -8
The interior is beautifully done! Your 'before' pics were intimidating. I am looking forward to seeing the exterior come together.
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Post by trailertrasher on May 25, 2016 21:56:03 GMT -8
Nice work!
Either of these look right ? <a href="http://photobucket.com/" target="_blank"><img src="http://i227.photobucket.com/albums/dd106/amctogo/IMAG4411.jpg" border="0" alt=" photo IMAG4411.jpg"/></a>
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Hamlet
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Post by Hamlet on May 26, 2016 5:11:20 GMT -8
The ones at the top are what Hamlet (59 Compact) had, but was missing one, so we got a replacement from Lowe's. You have done beautiful work, we have seen a roof like what yours came with before. Hamlet had a crashed in back half from a snow load. It's ok, he's happy now and we're looking forward to some short trips this year and a long one next summer. Have fun with your family. They will remember all the good stuff about the journey from near-junk to adventures on the road.
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chris
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1958 Shasta Airflyte
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Post by chris on May 26, 2016 10:42:25 GMT -8
Ah, trailertrasher! Thanks for responding! Someone suggested I PM you, but I don't think that as a new member I have PM privileges yet...
I believe the one at the very top is a perfect match. Mine are "eye-shaped" and three-holed just like all the painted ones in your picture. But where the sides come around, mine do not have those notches on the sides. The one at the very top looks notchless, although maybe that's just the camera angle.
From an old SuzieQ post I found some replacements online. I realize after all they're just closet rod holders. But it would be nice if they all matched and I didn't have to make even more holes in the walls.
Chris
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Post by Deleted on May 26, 2016 17:08:29 GMT -8
Chris, it was a pleasure seeing your photos. Beautiful wood and great job. Those kids will no doubt 20 years from now fondly remember the fun times you had and hopefully by then are still having. Best wishes!
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chris
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1958 Shasta Airflyte
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Post by chris on Jun 16, 2016 0:53:09 GMT -8
Got the new sides on today...
The sheet metal shop put the seams and the break lines in. Then I just clamp on the sheets and trace out the camper edges, windows, doors, etc.. I pull them off, make the cuts, and then stick them back up permanently. Going okay so far. All I have to do on the street-side is cut out for the fender and its done. Tomorrow, hopefully I can get the roof on and if the weather holds I should painting this weekend.
Now the good and bad parts about living in interior Alaska.
The good: I finished working and took the street-side picture at midnight because it was still light enough to do both.
The bad: Nobody in the state could supply the aluminum in sheets longer than 10'. So each of my sides is four pieces of aluminum instead of two. That means I have a vertical seam on each side, which I tried to place in such a way that they were as short as possible. The curb side is in the middle of the door, and the street side is cut by the kitchen window. I put the rear pieces on first then it is overlapped by the front piece. That way, crud is not actually blowing into the seam when you're rolling down the highway. They seem to lay pretty flat, but I may pop a couple rivets in just to make sure. There's no hiding them, but I don't think once it's painted, they'll stick out like a total eye-sore or anything...
I'll keep anyone who's interested posted on the roof installation. I mentioned on another thread that the sheet-metal folks put the acme seams in all the roof pieces, but I still have to put them together. The paint people suggested NOT putting any kind of sealant in the seams as I assemble them. They said to assemble them, prime them, and then run a bead of flex-seal down each seam before I paint. Any thoughts anyone?
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chris
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1958 Shasta Airflyte
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Post by chris on Jun 16, 2016 0:56:40 GMT -8
P.S. Yes, I realize the back cargo doors haven't been cut out. I figured they would be easier to paint that way. I'll cut them out afterward. That way the lines and everything will match up. Maybe not necessary. Who knows? I'm making this up as I go...
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Post by vikx on Jun 16, 2016 20:09:53 GMT -8
For not wanting a "show" trailer it sure looks like one! Congrats on such a great job.
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chris
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1958 Shasta Airflyte
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Post by chris on Jun 16, 2016 23:58:01 GMT -8
Alright, the roof is on. In a lot of ways this was way more straight-forward than I thought it would be. I'm posting a few pictures of the process in case anyone feels led to replace their roof with new aluminum. It really wasn't too bad.
The roof came in four 4' wide pieces. I had the sheet metal shop cut the length down to what the original pieces were. (Off the top of my head I think 85.5"?) They also bent the seams in the long edges (a Pittsburgh on the very ends and acme seams between all the pieces). First things first, I had to pound all the acme seams together to make a long one-piece roof. This was the part I thought would be easy, but it turned out to be a little bit of a pain. I laid them out on the shop floor and started pounding the seams flat with a rubber mallet. The seams like to pop out in the middle if you're not being really careful. I'm not sure the seams were put in super-straight, because when I finally got them all together, there were a few small bowed up areas. You could push them down, but it would just pop up another spot. Lesson learned: Take your time--pound them a little flat and pull the seam tight, pound a little more, pull the seam tight...
I threw some insulation up above the plywood ceiling and brought out the new roof. Luckily, some family happened to over at the house at just right time and helped me get it up there. With a ladder on each side of the camper, we just started at the back and pulled it up and over to the front. Easy. Now... here comes the pictures of my method of installation.
Step #1: Since I notched it about an inch for the back window (like the original was), this became the critical edge. So I adjusted the metal sideways until I had an equal amount (approx. 3/4") of overhang on each side. Than I adjusted it vertically to match the window edge and clamped it. I threw an extra 1x2 on each side for a nail strip and nailed it down.
Step #2: I went to the front and clamped on a piece of strut to hold it nice and flat. Then I used two ratchet straps from the clamps down to the frame to pull the roof tight. This worked way better than I thought it would. It sucked the roof right down to the tack strip on the edge.
Step #3: Time to bend the edges over. At first I only did the middle where it's flat. I wanted both sides tacked down as much as possible before I tried bending it around the curves. I started with a 3" hand brake. Then I realized I could do it a lot faster with about the same results by just gradually forming it over with a hard plastic mallet. Two lessons learned: First, keep the mallet on the roof metal. When I started, I was about half on the roof metal/half on the side metal. The side metal is thinner, and I didn't realize at first how much I was beating it up. Once the sun hit it just right, I could see some hammer marks and I started being more careful. Second, if you're abandoning the brake like I did, just work about 2' at a time. Take about 5 or 6 passes over the area you're working. It will slowly form over and make a nice rounded edge. I found this to be easier and to soothe my lazy conscience, I convinced myself that the softer rounded edge put less fatigue on the metal than a really sharp 90. After a few feet, I would predrill a 1/16" hole every 3" or so and pound some nails in. Then I would do the same on the other side, working both sides as evenly as I could, just in case I was slowly pulling it as I went.
Step #4: The curved parts. Once the flat parts were done, the roof couldn't really move anywhere, so I did the curved parts pretty much the same way. Here you can see there's a little radius to the bend. It's not a sharp 90. There's a little bit of wave as it goes around, but nothing the drip rail won't take care when it gets screwed in.
Step #5: Climb onto the roof and admire your handiwork. You can see the couple of bows I was talking about. I'm hoping a few days in the hot sun might relax it a little. We'll see... I'm not overly worried about it because you can't see it from the ground. On the ground, everything looks nice and straight.
Now that I understand the technique, I may actually start canning hams. Thanksgiving will be here before you know it and I have plenty of leftover aluminum...
I know most people who take their roof off are probably putting the same one back on, but just in case yours needs replaced, this was easier than I thought. I hope this helps and if anyone has any specific questions, let me know. Tomorrow, the front piece and back piece and then prep for paint. Woohoo!
Chris
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