[VAC] Re: New floor

[RJ Dial <rj.dial@xxxxxxx>]

         Reply to:   RE: [VAC] New floor
One thing that often happens on a shell off restoration, is that after 
the shell gets removed, the tendency is to remove the the existing floor 
and insulation, clean-up the frame, stand back and admire your work - 
and then realize as you start to lay down a new floor that you have no 
idea what the original floor outline was!

You can guess and come close based on the outrigger ends (but was it 
flush, in a 1/2", or did it stick over?), and where did it ended at the 
front and back?

Best bet is to either:
1- make a template
2- cut the new floor before removing the old
3- or don't remove the shell at all, but instead replace the floor in 4 
foot sections with staggered seams running fore and aft.

No matter if you replace in sections or do a shell off, you will have to 
get between the inner & outer skin to get to the fastener heads in 
the U channel.

Four Methods seem to be used.
1- remove the interior rivets up about 12" to loosen the inner skin for 
access.

2- cut the inner skin all around about 6" up and splice back on when 
done (I've never seen this work well, as you end up having to install a 
lot of fasteners to get the two sides to even out, plus often it just 
looks like hell.)

3- Cut little squares out at each fastener location, and then install 
Zolatone painted plates back over each hole (this looked very nicely 
done).  This method still required loosening the inner skin up to get 
the old heads and crap out of the channel and to locate the fastener 
locations.

4- Install 1/4" blind moly fasteners up from the bottom.  This usually 
results in extra holes in the U channel, as the holes in the frame and 
the new holes you drill in the plywood rarely match up with the existing 
U channel holes.  And you still have to loosen the skin to clean out the 
channel.

Anyone else got any methods while we are on the subject?

RJ
VintageAirstream.com>