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Old 09-20-2009, 02:38 PM   #1
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1992 Flagstaff - 8ft Project

Is this forum operated by Forest River or independent? Just curious. Either way I am happy to have stumbled upon it.

I have posted a thread elsewhere regarding my cheap purchase, and the process I've gone through to-date to get it usable. Thought it may be good to post it here as well. >warning< its a looong topic...lol. Enjoy.

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I just recently acquired a used pup, a 1992 Flagstaff. I've had a few others in the past, but this is the newest pup I've owned yet.

I only paid $100 CDN for it !!

Here's what the advertisement said:

Quote:
Address: Hamilton, ONDate Listed: 04-Aug-09
I have a 1992 Flagstaff tent trailer for sale for parts or to fix up
$100 firm
need gone asap or going to the dump with it
In any event I called and the story was the usual complaint that the trailer wouldn't pop up and that it has some 'loose trim' on the front end. Canvas was reported to be in good condition.

Here's what is looked like when I picked it up:



Was able to figure out why the lifting mechanism wasn't not working. Master link on the front chain was busted. Replaced master link and the front goes up and down now. Three of the four telescoping rods work fine now, and the last one is functioning but the telescoping rod seems a bit bent and hangs-up a bit when lowering it. Canvas appears okay, except for a very small hole in the canvas upper front corner which should be repairable. Hole is about the size of a quarter at most.

The roof is rotten on three sides. Top platform section itself is okay.

Here's what is looks like now. I think it looks just fine, and for $100 its should be just useable. Its only 8ft long, but will sleep the 4 of us and the dog.



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Old 09-20-2009, 02:40 PM   #2
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Note the duct tape on the front holding it together for the moment. Red Green would be proud of me!

Questions:

Are the telescoping rods and springs still available for purchase? This is a Goshen lift system. I'm intimately familiar with how they work now

I know how to get the telescoping rod out, and I know how to get the spring out of the rod, but I have no idea how to get the spring off the chain connection. Anyone have any words of wisdom here? I'm just not sure how to get the spring off from the connector, as I have yet to see an area where that connector is exposed for access. Should I see it when the trailer is fully raised, or fully down? I have the diagram of the system from the web.



Where is a good place to get replacement aluminum dimpled material (shown in red below) for the front of my roof? I have a friend with a sheet metal brake that can bend it for me. I'm hoping to bend it like shown and seal it up really well, rather than replace the entire roof skin. I figure if I leave the rear of the roof 1/4" low the rain should go that direction rather than pool at the front. Thoughts?



Thanks for reading. I'm hoping to be an active participant here. If anyone has any advice for me...I'm all ears!

/Chris
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Old 09-20-2009, 02:40 PM   #3
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08-16-2009

I made some progress today. I knew I wanted to get the lift rods out to clean them up, and I need to fix the roof.... so there was no use waiting. Time to remove the canvas. Took about 30 minutes to remove all the interior cushions, curtains, and canvas. Wasn't too hard. I did have to disconnect the wiring that is routed up to the roof for the interior lights.







I was then able to see the roofing material a lot easier, and to inspect where the rotten areas were.

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Old 09-20-2009, 02:41 PM   #4
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Old 09-20-2009, 02:42 PM   #5
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Old 09-20-2009, 02:42 PM   #6
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I built a 2x4 frame, added material to the supports for protecting the roof interior, then set the roof aside.





Pulled the side trim, end caps and side wood off.



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Old 09-20-2009, 02:43 PM   #7
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Old 09-20-2009, 02:44 PM   #8
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I'm stuck at this point, until I call a few RV places to see if they happen to have 1/2" in 4 x 10ft OSB. The side boards are about 8-1/2ft long, and of course the retail lumber places only offer it in 8ft lengths. I may have to lap joint it if I can't locate a long enough sheet.

I'll need to pick up lots of butyl tape as well. That stuff sure is sticky.

Not sure what to do about the upper roof material. Closer inspection shows this roof has quite a lot of hail damage. I'm considering EPDM rubber sheet over the top and front/rear ends. Then re-use the aluminum on the sides. Doubt I'll be able to locate aluminum sheet to do the top itself.

May opt to replace the roof vent as well. Probably the easiest time to do it and I notice a few hairline cracks in the plastic framing around it.

Progress for today has halted. Will call some RV places this week for more advice and materials.
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Old 09-20-2009, 02:44 PM   #9
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08-17-2009

I phoned several lumber yards, and one place that is known for specialty plywood. Also tried phoning some RV places to see if the had special length wood available. Came up empty handed. I'm sure its out there, I just can't find it.

Moving ahead, I decided to go for exterior grade ply 8ft long, and lap joint it together with PL Premium with wood screws. I will add wooden dowels (removing the screws) tomorrow once the joint cures.

I think it looks okay.





While at the building supply store today, I found some aluminum sheet (valley roof flashing) that is big enough to replace the front panel. Still deciding what is the best approach, and yet still economical. Its not dimpled material like the original sheeting, but I have read about some white elastomeric coating (Kool Seal) that can be applied to the entire roof, like paint. That might conceal my repair. The EPDM rubber membrane is too expensive for this repair. minimum order length is 21ft is near $600 from what I can see online.

Not sure if anyone is reading this stuff, but hopefully someone else who is facing the same type of repair finds it helpful.

Cheers.
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Old 09-20-2009, 02:45 PM   #10
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No real progress today. I did phone Goshen Stampings to see about getting lifter parts. They were nice to talk to , but quickly advised me that my lift system was not a Goshen system. Similar, but the rotary chain drive at the ends clearly made it the "less than reliable" Forrest River version and they gave me the number to call.

Then I spoke with a real nice gentleman at Forrest River who emailed me a bunch of documents detailing operating and maintenance procedures along with parts diagrams for the roof, and gave me the contact info for the parts department.

I hope to hear back tomorrow from the parts department regarding replacement springs and corner lifting posts.

Tried to pick up a sheet of blue denim colored formica tonight to cover the inside perimeter of the roof. The will be a better material than the original fabric (my opinion) and it also beefs up the thickness/stiffness of the side wood panels from 1/2" to near 5/8" which the old ones appear to be. I misjudged, thinking they were only 1/2". Apparently the stores don't actually stock formica anymore and wanted me to order it in. I'll find someone with something 'blue' in stock I'm sure.

Off to glue dowels into plywood lap joints....
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