Finishing the outside

After some time away, I had some time off to get the outside completed and ready to paint
I had to get the sides parallel and at right angles so the roof (That I kept) would fit- there was not much room for error.
After making sure I had the right distance at the top between the two sides I made up the window frames and supports in the roof and rebated them in.

Next I attached the roof, then the front and back ply cutting it to size to slip under and up to the floor.
It started to look like a caravan!

I painted the exterior of the plywood to seal it

Next I covered the caravan in some thin Insulation- I found some that is use for under flooring.

I then attached the old sides,  new  front and back alloy sheets and window surrounds, then the old roof.

Fixing the cracks in old roof

Finally I cleaned the old trim and glued it on and sealed it with polyurethane sealant. (You cant use silicone as the paint wont stick to it)

I cut out the hole to insert the new lights (New Landrover series 3 lights)

Trouble

Well, it appears that the smooth run was about to end.
First I noticed that there was a crack in the trailer frame, so I took it to get welded.
When attaching the floor I discovered that the frame wasn't exactly square or flat.
Hopefully its no major and everything will sit OK in the end.

Also, when assembling the axle and bearings, I struggled to get them on properly which caused one of them to get damaged, so had to get another set.
Here is a useful link- if you haven't done it before probable save the time and frustration and get someone with right tools..
https://www.etrailer.com/faq-wheelbearingpack.aspx

The day I decided to haul the sides out of the shed and assemble them outside (It wouldn't fit assemble through the door), it looked like rain was on the way.
With both sides up and braced- sure enough it started to drizzle,
We had to cover it quickly at the interior MDF hates moisture. In the process the wind blew one of the sides over- but there was no damage. Phew!

Completing the sides

Now with the template of the sides, I fitted in the window frames and door frames.
Next was the rest of the framing, pre-wiring the for 12V lights and plugs, insulation (Polysterene) and then interior lining.
Finally I put them together to make sure they were the same size, using a planer to trim edges.

Work on the steel frame- what it all sits on.

Once I had separated the body from the frame, I was able to get a good look at it.
There was some surface rust and where the stabilisers (the thing that you crank up under the back of the caravan when parked) attach, some of the metal had corroded.
The plywood frame had some rot at one of the corners, and the wheels had rubbed on the wooden wheel covers so needed to be enlarged. Therefore, rather than patch the plywood I decided I would replace it.
The plywood was riveted securely to the metal frame, so I had to crack the rivets off with an old chisel.
Once the floor was off I then removed the wheels and axels, put it all on a trailer and took it to be sandblasted, weld new stabiliser mounts, and drill out some of the holes (so I could attatch the plywood with  stainless screws from underneath). The frame was then sent for galvanising.

The alternative would have been to use a wire brush on a drill to clean the frame as best I could and paint it with something like POR-15 (POR-15 Link)
I knew this would not treat the inside of the steel box construction, I would not get all the rust out, and it would require more time. (This, however would be a much cheaper option by far and would suit those on a tight budget).

I will give a breakdown of costs in a later post soon.

The torsion arm  from underneath

Torsion Suspension 

"Torsion suspension is basically a swing arm style axle which pivots within a rubber or elastomer enclosure.
As load is applied to the axle the torsion arm turns within the rubber causing the rubber to compress on one side and roll on the other and as the load is released the rubber moves the torsion arm back to its original position.
This type of suspension can give a very smooth ride as the trailer rides over the bumps with independent suspension. Another advantage is that the trailer deck height can be significantly lower to due the lower profile of the torsion unit.
There are a few disadvantages to torsion suspension as follows. Torsion suspension load capacity normally maxes out at 2500kg towing capacity" From "Trailer Sauce"
We should be OK with the weight limit depending on what my wife wants to pack!

Now we have a solid frame to build on...

Start of the rebuild- the sides

Now that I had the sides off, I see what could be used.
The fibreglass was removed from the sides and put aside. There were several holes from some of the old fixtures and it was torn completely above the door, so I made a note to order fibreglass repair kit.
Poking a screwdriver into the frame revealed that all the wood, apart from around the windows, was affected by water damage so had to be replaced.
I brought 5 sheets of treated 8mm ply for the sides, and 10mm for the floor
I butted the plywood together in the best position for later fixing and cutting. I used the old side as a template and laid it on the plywood.
I then drew around one of the sides making the pattern.
The caravan started taking shape.

Lining up the guide on streight sections for the Skill Saw, the curves were cut with a Jig Saw

Last of the demolition

After the insides were stripped out, I pulled off the beading around the edges, removed the alloy panels that covered the top, front and back, then the fibreglass sides.
The one on the door side was cracked and so came off in two pieces.
The covers over the wheels were removed, then with some strategic bracing the plywood sides that remained were removed from the plywood floor, and the floor, with the steel frame pulled out from under.
The sides were then separated.

Body propped up, before frame and floor pulled out from underneath

The broken door frame and attempt to strengthen it with aluminium

The front and roof removed

Demolition interior

The Cabinets were all sound, but didn't make use of the limited space well, and I wanted to change the layout, so apart from the original handles and one of the cabinets (that I hope to maybe use as a template) it all went in the trailer.
Unfortunately as I started pulling things out the worse the interior looked.
I realised later it was only the cabinets holding the wall up!

The rot starting to reveal itself under the front seat...

The old basic kitchen

Water appears to have come in between the walls and caused the wood to rot.

The silver lining paper was in between the thin ply and alloy sheet

A few close ups...

Just the begining...

This caravan was purchased site unseen, thinking that it would be an easy interior renovation job and would need just a repaint on the exterior. I got it re-registered - it having lapsed ten years ago - and had the seller fix it so that I could move it legally. 

I then drove down to the seller, picked it up and towed it proudly home.

I took some before and after photos of my project to see the progress I had made on the caravan, then I realised that there was a lot of interest on this kind of project involving the restoration of a Caravan, so I decided that I would share my restoration journey with anyone who would be interested. 

You will be able to have a few tips from me about the restoration process and spot some of my mistakes...

Inside roof lining -old lamp

The kitchen- no gas stove. Love the lino!

The wardrobe and single bed- nice curtains!

Restoring a 1976 Pioneer "Petite 10" Caravan.

I have always enjoyed pulling things apart and putting them back together-this includes restoring two VW Beatles, a Series III Landrover and several houses. I needed to find a new  project, having just moved to a rental property.

The following article will be about the renovation/ restoration process of a 1976 Pioneer Petite Caravan, which I brought on Trade Me in June 2016.