It’s spring !

And the Frontier is on the TODO list..

Soon …very soon I will be moving the Frontier to the driveway in front of the garage and start working on the list.  But for now I’ll pre – – build some of the panels so they are ready to install.

Here’s the charging / info panel that will mount below the thermostats and the existing panel.  Powering this on will give me an accurate battery level.  I also made a smaller USB panel to mount near the dinette for charging and powering electronics.   I’ve checked out the wire routing and I can do this.

The Frontier is in front of the garage now and I stared work .  One of the first things was to get the “tuck” tape off two of the hatches.  Yes that was the fix for doors that would not stay closed !  My fix was to install new latches…  done.   And I’ll stick to working on the outside for a bit..  Removed the bush bar Spare tire mount from the van.  It’s getting a new paint job in the shop..  And with a color matching the van.

I can use the same paint to touch up the rust spots on the van.   Oh and the Frontier got a bath…  a good scrubbing for sure..

These photos don’t really show the difference.  Maybe this one does..

Yup looking spiff.   When the weather warms up I’ll do some wax too.  In the mean time I really needed to get the roof and the vents sorted out..

This will be part of that work.  A new Max Fan for the rear vent opening..   And vent covers for the other two.  In fact everything on the roof is getting attention.  It’s taken two days but I got the roof to where I can say it’s leak proof.   New vent covers , New fan, New plumbing vent cover..  and the TV antenna is removed and nicely patched.   Let it rain !

time to investigate more of the secrets inside the cabinets..   First off the mystery Bus heater..  It runs constantly when the ignition is on..  There’s a thermostat on the wall that is suppose to control it.  Not working..  So I took the panel of..  and found this green thing ..

Well it’s an aux heater..   plumbed into the motor coolant lines.  And it appeared to have a small leak !  And the control box  was most likely the cause of the control not controlling stuff..   I thought about it and I really don’t need this heater..  So here it is ..  and the long hoses connecting it are gone.  Now I have a power wire I can use for something else. and more storage.

Nice day today.. So I got to work installing new Led lights..  Then I could get the vent trim back in place.

This new light takes care of the holes left from the TV antenna.   Over the table it could be handy.

This one is just a bonus… wires were handy.  Next the light over the sink..  The lights over the couch and the dinette are remaining the old ones they are cool and work good.. just changing the bulbs to LEDs.   Because of the circumstances in the world and here in BC  going camping is not happening for awhile.. so any more work on the Frontier will wait till other things are done.  I have a list..

It’s May…  the weather is getting warm..  but the camping season will be delayed till the Government opens up the camp sites.  My work on the roof has allowed the Frontier to stay out in the driveway ready to pick away at some odd jobs.  Like the rusty patches on the front of the hood.  And the paint chips .

I matched the paint very well and hard to tell unless you get very close.  Once this job is done I can re mount the guard on the front..

Done!  The real purpose of this is to hold the spare tire.  I’ve taken the dash apart and wired the new stereo properly.  But I still have more wiring to do..  like running lights.

Some things won’t get done..  but new things have popped up like the power converter.  And it had to be fixed..  Luck for me we had a spare..  newer one too!  While doing that the closet floor had to be removed …So all those issues got fixed.  Also the USB / power center got installed .  The whole interior got a good cleaning and all the appliances tested..  Ready to go.

Now that the painting is done and had time to cure …  it’s time to get this puppy buttoned up…  Spring is here and I need the shop for other things.   And I’ve decided too sell the Acorn without doing anything to the interior.  The decor is a personal thing..  I provide the solid “like new ” trailer and someone gets to personalize  it.

The windows are going in..  and the door is next.

Also the fridge vents are painted and back…

Today was a very nice day..  Perfect for putting the body back on the frame… and we did just that..

Now I feel confident enough to mount the door and adjust it properly.  Once that is done then just need to wire up the running lights and install the roof vent and it’s good to go..

Well and bit of a snag.. the door is not fitting !  When I bought the trailer the door was mounted but hanging down because the floor was cut away on the hinge side..  So there was no way to see the fit..  It’s obvious the door in a newer one and not the original.  The problem is there’s not enough curve to match the door opening.  Now it could be taken apart ..a template made and the curve changed..

Here you can see the gap at the top….

And the bottom too !  When I formed the body I was careful to keep the door frame parallel and straight ..   But the curve is molded into the body..  and the steel brace behind the hinges is pre-bent to the proper curve..  ?  So what to do..   I have an idea..  temporary but will keep the rain out .

Well the Scamp is done !  Outside and for sale.  Looks good with the moons on the wheels.

The ride height is good.   The lights all work as they should.  I’m putting all the cabinets back in place..

So now we will see if someone wants a bit of an interior project..

And yes they did… SOLD  to nice folks from Kelowna

There is not near as much body work needed as was for the Boler.  No pool paint to sand off..   While the body is still laying on it’s side I’m going to fill the holes in the roof and modify the roof vent..

And then with a little help..   The Acorn is back on it’s feet (wheels).

Ya we rolled it inside the shop..  Only a little grunting..  Now I can get the body ready for paint..  That requires filling holes, cutting the side windows bigger, and finish up the roof vent.  I have already fixed the lower skirt in the rear of the trailer…  so we are part way there.

I’m almost ready for paint !  just cutting the openings for the three replacement windows.

Slightly larger radius windows..  Good thing we are doing this now … I realized the holes in the corners needed filling.

This was the only crack I needed to repair.  And I believe it was caused by the weight of the door without any floor or any thing to support it.  But !

There was a hole for the heater that I don’t have..  So I patched it..

Now ready for painting…..

First step is the primer…   Bushed out the places the roller won’t go and all the patches..  so I can see how they look and if a little touch up is needed before the paint.

And there you have the primer… just the first coat….

And moving right along..  After the second primer coat was dry..  and sanded..  I’ve got a first coat of the white & the gray ..  I’m needing more of the whit so it’s off to Kelowna for more..

Still needs a second coat on both top and bottom.. but you get the idea..  Scamp’s were normally all white.. but not in my shop..  I figured the gray would balance the trailer and it’s neutral enough to be pleasing.

And now with the second coat..  the Scamp is not looking shabby ! So on to the interior painting.  I got some really good paint for that..  But first I’ll need plywood glued behind some of the things like the fridge vent covers, water fill and drains and the electrical hatch.  Reason…  no more rivets..  I’m using stainless steel wood screws.  And they won’t hold in just the fiberglass walls.

Now it’s time for putting things back together…  New post

Re-Assembly Time… Page 6

Well it’s December… it’s cold and time to get to work on the Acorn…

Just like “Scrat” here the Acorn trailer is a lot of work…  And replacing the floor was no easy task.  The body is held up by the floor and the floor sits on the frame…  All three must be strong, it’s the integrity between the floor and the body that is key to the trailer’s life expectancy.  The floor completes the “egg shell” .   Now that the floor is installed and glassed to the body on the top side…  I need to do the same under the trailer too.  Only one way I see to do this is to lift the body / floor off the frame and roll it on it’s left side to have access to the whole bottom.  Without the windows and no door the body is light..  but i will need to install some braces inside to keep away any sagging .  First thing to do is build a dolly that will cradle the body on it’s side.  With wheels so I can roll it into the shop.

So I built this dolly…  We lifted the Acorn from the frame ….rolled it over… and!!  It was too tall to fit through the Shop door !  Fine… Got a piece of carpet and we slid the Acorn off the dolly and into the shop.  Good thing it’s not too heavy..

And there we have it..  Looks like it fell over and died..  Nope all is good..  Easy to work on the underside now.

Got up this morning and SNOW…  boy did we get the Acorn inside on the right day !  Not a lot of snow …just an inch..but makes it hard to lay on the ground and jack the body off the frame.  Going to leave it in the shop for a few days to warm up and dry out ..  Seems the tarp was leaking a little but no damage done..

Here’s a small video I made…

I don’t seem to have a lot of ambition around this time of year.. but the Acorn is there when I do…

It’s into February now and I’m doing my best to get this bottom all done…

Here I have all the glassing done.. It’s taken weeks and a lot of resin..  But I got R done…  And then came the decision of what to cover this with…  I want it black..  And i want it to further protect the underside of the floor.  I thought about epoxy truck box liner..  But the price was very high..  This is more area than a truck box..  So it takes two kits..  I settled on good old enamel..  same as the frame.  and it was easy and quick to roll that on..  Two coats and we are done.

Next is to attach a dolly to the underside ..  and  while the roof is easy to get at I want to enlarge the vent to a 14 x 14 normal vent size.  And I want to glass a wood frame on the roof so the vent is raised and some stiffener added.

Here I have the dolly..  taken apart and mounted to the underside..  Mounted only through the holes for bolting the frame.. NO new holes !  When it’s time to put the body back on the frame. I just lift it and remove the four lag bolts and the wheels will fall away..

Now for the body work…   Onward to PAGE 5

Frontier Class B Wide Body Van Conversion, Model XL820

Here it is!  It’s not new.. and could use a bit of love.  I’ve only had it for a day or two..  The love will have to come next spring, it’s getting late in the season..  And please remember we are 38 years old..  A senior citizen in the world of RV’s. So you have to excuse the rust.. and the retro decals.

Where do I start…..  Not expensive  I bought it with cash.. And yes this will mean we have two RV’s..  But this one has a hitch and I can tow my ATV… or a boat… or anything..  It’s very compact for all the stuff it has… 21 ft from the front of that cow catcher to the back of the bumper.  It’s like a LeSharo that you can actually use / drive..   With a real motor !  In fact we had a heart transplant 30,000 kms ago..  With lot’s of new parts..  It now has new tires too.  and drives great

And here’s the door !  Different !  but it’s a design that works… I like it. The Frontier was made in the Vanguard factory Winfield, BC..  And you will see more of the Vanguard version on the roads ..   Rare yes..  They only made these for a few years before the recession hit the RV industry.  It’s hard to find any info on the web for these…  That will all change with this post.

Here’s the interior.. very typical color scheme for the year BROWN !  The fridge has been replaced..  and the lino is newer..  but the rest is original..  And all in working order..  Just needs a good cleaning..

The floor steps a bit lower in the rear of the camper.. and that’s where you find a small kitchen and a wet bath on the drivers side. There’s a extra counter top you can lift up if you need it.  No oven .. no microwave..   Who uses those things when camping anyway ?  We cook outside.  BUT you do make coffee inside in the morning.

Here’s the biffy..  Works for me.. I’m not likely to use anything but the toilet. But you never say never. It’s very clean ..so nothing to do but change the light to LED.

So lets talk about the Van part of this camper.

That’s typical motor home fair ….  except !!  just a 350 motor.  Yup it’s the tried and true good old 350…  but this is duely  ..so heavy duty trans…  and stuff.  And like I said earlier… new motor 30,000 kms ago.. Work done  in Ontario !  It’s been places for sure… This summer it drove out to Sask and back with no issues.  And it just passed a BC inspection.

Look at the interior … it’s almost perfect..  I have not cleaned any of it..   Power locks , power windows, A/C that works..  cruise control, new stereo..  You know I’ll add to that list..  I’m thinking remote locks.. more power plugs…  back up camera…a digital volt meter for battery condition.. just to start..

Nov 17 th 2019:

Today I gathered up some ambition and plugged the Camper in to my 30 amp.  Everything works as it should..  But the extra furnace is  a bus heater that works from the motor heat. And I think works using the wall thermostat.  For sure it powers up when the van is running.    The RV propane furnace works great..  As expected the new 2 way fridge works..  I found the pump and water tank under the sofa..  Tank is empty and there is antifreeze in the water lines…  But just to be sure I ran another jug through…. No problems.  No leaks ! It’s all good and it’s time to put the Frontier away for the winter.

The tarp is extra insurance.  Not really needed but what the hey..  I feel better with it on cause I did not install the vent covers..  One or both of the vents will be replaced in the spring with better quality ones.. The current ones have plastic frames. And I’m thinking a power vent will be a good thing to install.   The Frontier (like most) is wired for a rooftop A/C unit..  I have one, but I don’t think it’s needed.  Going to find out this coming summer.

I’m going through all my collection of stuff for RV’s, And making a war chest for the Frontier for next spring..  Here’s some of the stuff:

What do ya know I have the remote locking stuff…  with two fobs!  I have lots of LED lights , switches, USB charge ports, and a host of other goodies to make life easier while camping.

I’ve had the motor antifreeze beefed up and checked..  Last thing I want is for that to freeze over the winter.  As soon as I get my new GoPro camera I’ll be posting some videos… if we are not buried in snow.  But first one made with the old camera….

And it looks good..  I expect the new GoPro to be even better.  There’s a screen on the back so stuff won’t be missing from the shot.

We were thinking about the sleeping arrangements ..  So I went out and pulled the sofa into the bed.  Not big enough for two.. so the dinette will be used as well.. and what do you know!  There’s room to walk between.. nice  The spare tire was blown… really bad..  So I have a new tire coming.. and because the other six are new this year too.. it will be a perfect match.

Now I have a rim with no tire… And you betcha I got to paint it..  One hubcap is missing …and I’m not crazy about them.. Kinda feel like I would loose more over time…  So I’ll paint the rims instead.

And NOT RV white !  This is my concoction I mixed up..  Half Aluminum half grey… and a dash of black.  Nice!  This is the only wheel I can paint this year..  The others will get this treatment next spring… And here it is with the new tire installed.

And that’s all till spring when the time is right for fixin up…

1982 Frontier Class B+  Page 2

I did it !

Traded in my much loved 400 quad for a side by side of the same vintage.   A 2014 Polaris RZR 570 trail !   Perfect..  even the nice blue I liked and choose when I bought my Quad.

Nice looking !  I’m very happy to put this in my garage..  The 570 is the perfect size..  Plenty of power but still good on fuel..  AND this is the trail version.. which is only 50 inches wide..  2 inches more that the quad.  That means the it fits on ALL the trails I ride on AND carries a second person.  AND more stuff.

I plan to make a custom box for the back.. with a lid to keep all that stuff dry and secure.  But before I get too much into plans for Pimping this ride..  let’s talk about what I don’t have to change..

This is the loaded RZR 570..  called the LE model.  And it comes with options like power steering, engine braking and nice alloy wheels.  All things I like and would choose.  NOW let’s thank the previous owner for adding the other things I like..  a roof , a windshield,  bush bar, 3500 lb winch, a horn..  and Turn signals?  yup LED turn signals.  The dealer added new tires , belt and a clutch kit … and we are good to go!.   So what else could I possibly add ?   Well lots !  Let’s start with a rear view mirror.  A must have.  and a bag that fits between the seats and holds your lunch…and other goodies where you can get to them.  Then I need my GPS mount and a second 12 power outlet for that.

What about more lights !  I like to have daytime running lights…  safety first !   And below them are the rear lights I will install..  Just in case.  I ordered a nice switch for those..  ( haven’t used the running lights yet )

And once again … just in case.. you never know..  Although highly unlikely…  A Sasquatch light ..

Ok..  it could come in handy as just a very bright light for tunnels and other dark places.  Most people call them a light bar.. LED of coarse.

There’s a nice place on the bush bar for it..   OK that should do it.. Can’t think of anything else right now..  NO I don’t want a stereo in my ATV.. I want to hear the animals as they run screaming..  Actually the motor makes enough noise and I value my hearing.  I will post more in the spring when I install all these goodies..

It’s spring !   And I’m really wanting to get out and put this wonderful machine through it’s paces.  I can carry it in my truck..  I got some nice aluminum ramps for that.   But I really want a trailer to pack it around..  Found the “almost” perfect one..   And here’s a post I started for it..   ATV Trailer.

So I’ve been for several rides now…  I have all the goodies installed and love this ATV..

This is my LED light bar…  and boy does it work well.. already used it on a late night ride.

This is my LED back up light…

And here’s the trunk..  excellent at keeping things clean and safe.

The new dash looks like this now..  moved the horn button… and two new 12v plugs one one the top of the dash for the GPS and the one you see here with a volt meter plugged in..

On one of the many rides.

I’ve been thinking of how to do this big job.  Good thing I saved the old floor pieces.   I’m going to use 5/8 GIS ply to build the floor.  And the frame will be the template for the lower floor pieces.  But the first step is to wheel it in the shop…

So I installed the wheels on the cradle and two of us pushed in in easily.  And as you can see the windows disappeared quickly !   Aluminum rivets are easy to drill out..  Still a few bits to remove.

On the cradle it’s a tight fit.. but it must remain that way until the floor is secure.   However I’m going to push it back out to the driveway and see if the pressure washer will remove whats left of the Thinsulate from the interior.

That’s about as much as I could clean off..  not bad.  That glue is tough stuff.  Which is ok..  whatever I stick on there will stay.

I carefully removed the upper fiberglass lip from where the floor WAS ..  So now I can drop the new floor in and it will rest on what’s left of the bottom lip.  Then the top of the floor gets glassed in..

I also very carefully cut out the new front and back floors.  The body came back in the shop..  And with a wire wheel I finished what the wash didn’t..  Real messy so it’s better without the floor.  Then I glued the floors in with PL 9000.

Glue is good.. But next I will glass in the top.  Only then do I think the floor will support the body.

This is working out very good..  After I got two good coats of resin and cloth on the seams… and I repaired the crack over the door… it was time to set the body back on the frame.

And that’s exactly what I did.. Plus I could take the cradle away.  Because now there’s enough floor to support the body.  The fit is very good.  Wow.. that doesn’t happen every day.

Even the “front to back” alignment is good.  This will be a great way to accurately build the lower floor.

You can see I used the 12″ naked rims to roll the frame back under the body..  Lower is better !  Plus this fits under the garage door when I want to move it in or out for more room.  It’s TIGHT in the shop..

But less tight then when the cradle was on the body.  It’s nice to see the trailer straight , supported and back on the frame..  even if it’s temporary.

Jan 15 2019…. A new year !

And I’m back to work on the Acorn after a bit of a break..

Carefully piecing the floor back…  Lot’s of gluing and fitting .   As well I got the fenders back in and glassed in place.  I was going back to work for the spring so I bundled up the Acorn and parked it in the RV carport …  with plans to carry on in the late fall .

Acorn Restore page 4 : Glassing the floor

Well this one made it into the shop…

And wont be cut up..

Over all..  it’s not bad.  The main frame is good, only some of the thin metal is rusted through.  And other than a different bumper , there has been no repairs or modifications.  I still don’t like how flimsy the frame is…  definitely relying on the floor for strength.   So that is what has to change.

This is an interesting thing..  It could be ( and most likely was) a space for a porta potty.   But it could be a front table for two.  Instead of the bunk.   Something to think about.   Now’s time to have a careful look at the frame. And make some plans…   This is my plans:

The Plan:

First..  This floor space.. without any support needs more added.   And the longer I looked at the bumper… the more I think it’s fine.  It’s strong.. and that’s important.

This is the rear of the lower floor.. no good like this.. I’ll cut it out and use two angle pieces.

The support for the entrance is..  well gone.   So I’ll build it back with more angle.

Surprisingly the axle is still good.. looks bad but it works as it should.  But I’m still going to use the new 2000 lb axles.  They have the hubs I need for the new wheels.  I will copy what I did for the Boler frame. This will add 2.5 inches in height to the trailer .   These trailers are  much too low in my opinion.

Lastly..   A new  2 inch coupler..  and a jack that fits the hole.  The holders for the propane tank need to be reworked to fit a battery in that space to.

Let’s Get Started:

Cutting and cleaning is the order of the day..  Getting rid of the bad pieces.   The place to buy metal is closed for a few days…  so I’m taking my time to remove the axle..  not easy when they put a weld in a tight place.

But I got it !  The axle and all the bad metal is gone..  Now I’ll do some grinding and cleaning to prepare for the new metal.  and I stoped to make a video…

Well the order in which I do all those mods doesn’t really matter.  So long as they get done..

So I started at the front of the trailer..   Here I’m seeing how things fit.  Yup this works..  Because the jack is tall the battery box can be in front of the propane tank..  Sooo

I made a battery holder !   I also made the seven ears for the body hold down bolts.

And now I have welded in the added rear frame floor supports.  Then we flip the frame over to work on the axles.  Pretty much following the same design as the Boler..  The axles are the same.

One difference …  This time I gave the axles a little camber.  And since the upward angle is 22.5 deg.  instead of the factory 10 deg.  even with the added 3 ” blocking..  we end up lifting the trailer 2 ”

There’s a 2 ” receiver under the bumper..  this will be used for the spare tire.  OR  a bike carrier.

The body hold down ears are done.  Seven of them just like the Boler.

The propane tank and battery holders are done too.

Once I’ve finished the door floor support..   I’ll flip it back over and time for painting.

There… underside is done.. and….

The whole frame is done..  just the wheels , hubs and stabilizer  jacks to clean and paint.   When the frame was dry I kicked it outside so I had more room to clean the wheels & stabilizer jacks.

All done..  took the wheels down to bare metal..  nice !

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Here’s the finished frame..  with it’s new tires.  This brings the height to it’s full and proper place.  A perfect  15 inches of hitch height.  8 inches of overall clearance under the trailer..  and a 10 ” entrance  height.  That in my mind is as near perfect as it gets.

The final touch arrived …. baby moon hub caps.  Can’t wait to see them on..

One last photo…  This is what the hub caps look like on the wheels..

On to the floor…    Page 3  The New Floor