[VACList] Floor Repairs

["Brian Jenkins" <jenkins1924@xxxxxxxxxxx>]

Hello All,

I recently replaced the entire rear floor section of a '65 Safari, and 
during this adventure I discovered a new (to me) way of patching unsupported 
areas of flooring. By far, the best new tool I've found recently is the 
rototool. It is an electric saw that uses modified drill bits to cut. Many 
manufacturers make them now, including Sears. They are perfect for removing 
flooring, as they can be set to the exact depth of the plywood and then you 
can cut directly across beams, holding tanks, anything below the floor and 
it won't even be scratched. Even if you hit a nail there's no kickback, as 
the bit simply breaks off and you replace it (they're cheap and come in 
packs of 5). You don't have to drill a hole to start the cut, you just push 
the bit into the wood.

Here's the method for replacing small areas. Make sure you buy a tool that 
comes with an adjustable angle base and set the base for 30-40 degrees. On 
the floor, draw a square of the area you want to remove and then temporarily 
nail four small guide boards to the floor about two inches outside this 
square. After setting the depth of the cut, turn on the roto tool and run 
it's base plate around the inside of the guide boards. You should be left 
with a clean, mitered square hole with the damaged floor in the middle. Now 
simply pull up this piece and cut a matching one out of good wood, either 
using the same method with the rototool, or on a table saw. After getting a 
perfect dry fit, coat the edges of the hole and the repair piece with marine 
epoxy (West System or similar) set the piece in place and put some weight on 
it until it is dry. This style of repair is used on wooden boats ( I know, I 
had one) and will last the life of the trailer, since the epoxy bond is 
actually stronger than the surrounding wood.

Brian Jenkins
'56 Overlander, '57 Caravanner