All back in...finally !

Its been a while since I posted but despite the best intentions to get her ready in time for summer camping, work yet again conspired to get in the way at the wrong time. So we're just back from a lovely but aluminium-free fortnight under canvas...in our trusty yurt.

But before work kicked-in, I did manage to get this little lot done...

Finished running the colour-coded wiring for the 12v (Blue), 240v (Orange) and running lights (Black).all hidden behind the lower panels. Leaving junction boxes & outlets where needed.I re-used all the old panels as they were in pretty good shape

insulating them on the inside between the framesDrill...Rivet...Rivet...Drill...

Rivet... Repetitive but satisfying.Still using a depth-stop on the drill bit.I refitted in the order they came out (of course). Ends first...And then the sides...Now you see it......now you don't.Last to go in was the small one to the left of the door.Two repairs needed before she was sealed-up. First; another heavy aluminium plate in the inside of the sieve-like door hinge plate...Vulkem...Clamped...

... and riveted, ready to take the new hinges.Second; a very localised bit of corrosion above the door.I decided a small patch would look more obvious than a larger oneso removed a section that was the full width between two framesand lapped the new piece over the edges of the old onesso the rivet lines matched those already thereOnce its got a new coat of Zolatone, it should hardly notice.So finally the panels that came out in the autumn of 2008 are finally back where they belong.and structurally even stronger than she was in 1953 Now to prep the old paintworkand mask all openingsready for a new layer of ZolatoneCabinets too...

Just the endcaps to cover.and since Zolatone (UK) were offering a good deal, I've decided to get them to spay the new paint.

Wires and skin...

Insulation on the inside of the outer skin, time to run some wires

We'll be boondocking more often than not, so no need for a monster dual system

Just a good 12v one

The old wiring (see older posts) was in a pitiful and dangerous state, so rather than rubber grommets or short lengths of tube (as Airstream used), I opted for rigid cable outlets

That screw tightly on either side of the C channel frames

A bit of colour-coding too - Blue 12v, Orange 240v, Black 7 core trailer hook-up cable

The plan is to have a 12v circuit for lights and using the 3 core cable will allow a dedicated line for the fridge. The 240v circuit will consist of maybe 2 double outlet plugs at either end of the trailer - since we'll seldom be in a full-hook-up site we thought it easiest to have plugs to allow us to plug in appliances if ever we are.

We have tried to plan ahead and with solar panel technology improving all the time (& prices dropping too)

and wired a dedicated charging circuit to potentially link with two roof-mounted solar panels

I've recorded where the two wire coils are, so, in theory, I should be able to drill through the roof panels and pick up the cable - well that's the theory !

To keep things simple, and to have as few breaks in the cable as possible, I'm sticking with the old system of having light switches on the light fittings, so cable loops are left at the matching holes in the inner skin.

Now to get the inner skin back in

First a layer of the Airtech insulation on the inner side of the inner skin

Its pretty clear where the rivet lines are on the skin, so I taped the insulation to the skin in sections, leaving a good strip clear where the skin touches the C channel frames as both the Airtech & the aluminium tape tends to grab and snag any drill bit.

Then up she goes...

 a bit of a bit of a fiddle but with a couple of extra pairs of hands and a pocket full of Clecos

it was fairly easy to line up the original rivet holes

The double layer of Airtech should keep us snug, or should Britain ever have a scorching summer, cool !

 Starting to look like the old girl again

Pop rivet-tastic...

4mm x 12mm with the odd 8mm - you get through a few hundred faster than you think

Although the inner endcaps aren't comletely polished

we had concentrated on the edges, where it joins the Zolatone (or what will be the new Zolatone)

- a nice juxtaposition of my inner endcap & the 54 Flying Cloud's outer endcap

Now just the lower panels to go back in

then prepping for the new Zolatone

... and a tad more polishing.