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Old 09-10-2014, 02:40 AM   #1
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Rebuild of front bunk end door

I brought home a 2004 surveyor, and found on our 1st trip that the door had rotted out. Here's the rebuild so far. I sawed out the remaining plywood and foam, and welded in a 2x2 aluminum frame. This will be covered both sides by fiberglass reinforced paneling and styrene foam inside.
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Old 09-10-2014, 02:44 AM   #2
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Btw, this is the bunk end door on the the front. It looks like this will end up about 12 lbs heavier than original. Also having bear creek do a new tent, as the old one tears if you look at it wrong.
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Old 09-10-2014, 07:30 AM   #3
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Wow. You do good work. That is gonna be one nice strong bunk end.
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Old 09-10-2014, 09:36 AM   #4
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You need to remove the outer trim and the filon and luan from the outer frame. after laminating new filon and luan, trim down to the frame with a router then re-install trim and seal.

I had to do one on a Kodiac 23TT. Mine had a very good internal aluminum frame already.
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Old 09-10-2014, 04:12 PM   #5
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There won't be any Luan going back in. This will be only aluminum/ styrene foam/and fiberglass reinforced paneling. The remnants of the Luan are there because there was just enough of the resin/glue to make me worry about deforming the frame trying to get it out. The frp paneling will be flush with the original frame on top of the remaining Luan.
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Old 09-11-2014, 05:58 PM   #6
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The smaller 1" tunes are offset to the inside to support the paneling/mattress. 1" thick blue styrene will be cut to fill in the gaps and make a 2" total thickness . Still have some welding to do. I didn't have the money to buy a water cooled torch, so it goes a little slower.
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Old 09-11-2014, 06:40 PM   #7
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You might want to shoot some spray-on foam into any of the aluminum tubes you can access (once you're done welding, of course).
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Old 09-11-2014, 08:21 PM   #8
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I had considered the foam, but all of the ends are closed and welded up. There was always the option of drilling each end and injecting until it came out the other end, but I'm still debating that one
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Old 09-11-2014, 08:25 PM   #9
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Quote:
Originally Posted by Hemifish69 View Post
... I didn't have the money to buy a water cooled torch, so it goes a little slower.
We have the same problem with the Lincoln Square Wave Tig 175. About 30 minutes max before cooling it.
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Old 09-11-2014, 09:28 PM   #10
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I've got the tig Eastwood sells. Bought it to do a project car, and I wasn't ready to drop the coin on a miller. Pretty good unit. Does the Lincoln have hi freq for aluminum?
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