My 61 Airflyte wheel wells/fenders were in rough shape so I decided to make my own/new ones with heavier gauge cold rolled steel that should last longer then the camper now! Started with the steel and actually used the old fender to use as a template to make perfect matches. The side of the fender actually isnt attached other then a thin lip that is slid into a groove so I just took a rubber mallet and tapped it out and used it to make the new sides exactly the same size! Then I measured the middle and cut those to the same length and tacked them in place! Piece of cake! Welded all the way around the radius to make sure they are water tight! Sprayed with epoxy primer and bedliner to seal out moisture! Installed and fit perfectly! I guess I should show what I did to the wheel well openings BEFORE I put the fenders in place. I put tin around the opening and used a roofing sealant to completely cover the wood so I dont end up with rotten wheel well openings again! So after I fabbed up the tin I installed the new fenders! Put new butyl tape around the edges along with new nails to hold the sound board in place and put that down next! After a little trimming around the new fenders, the new plywood went down and I danced a little jig on the new floor! I have to say that I am pretty proud of my trailer so far and I am looking forward to finished product but it is so much fun working on it! When the weather isnt -5 outside! OH I almost forgot about my new brakes that I installed before I put the floor in! PRETTY PROUD OF THOSE TOO!
The biggest problem I see about your fender wells is in 50 years the new owner won't be able to complain about them being rusted out. Looking good, keep on having fun and before long you will be there.
Last Edit: Dec 31, 2013 21:47:53 GMT -8 by bigbill
Outstanding job!! If Shasta and the other makers built like this back then, we would not have to be doing this now!
But the trailers would have cost 5 times what they did and not many would have been made.
Well that might not have been all bad, in that case they wouldn't be so available and we wouldn't be addicted to fixing them. I been wondering about trying to invent an electric trailer that you could just go and sit beside and get the same satisfaction, what do you think.
Thanks for the nice compliments and I guess the reason I'm building it the way I am is to one day be able to leave this camper for my son to enjoy if he so wishes. I know I will probably have to make repairs on it again some day buy I'm trying not to have it be so bad! :-) I will tell you that this forum and vts and the Shasta forum have been such a huge help and mobiletechs videos have taught me a ton so I'm just trying to do it justice!
Awesome job on the sheetmetal welding! I never thought of lining my siding with sheet metal--what a great idea. I mIght still be able to do that...I hope it's still holding up and you're getting good use out of your trailer
Okay, sorry for the empty post! It looks like I'm probably going to have to fabricate new wheel wells too. The flanges on mine are so thin and rusted that they've torn. Perhaps you would tell me what gauge steel you used? Did you wire or stick weld (I only have stick) and would you use a 1/16th rod for stick? Also what is the purpose of the wood sticks you have inside the wheel wells? Are those for support as you work on it so it doesn't cave in on itself? My other choice is to fabricate them out of carbon fiber and kevlar...or have someone else make them. Oh such choices... CF/K would be awesome though and for a lot less than the $1,100-1,500 online. Thanks!