This will include the new vinyl flooring and some of the wiring:
But mostly I’m doing the fun part.. Lights !
Like these LED stop / turn / tail lights. These are a boler must have. I’ve been fighting with the door.. it used to fit better.. turns out my new door gasket is to thick.. so I took a knife to it and “pared” things down.. a lot ! fits now and closes the way it should. Will need some foam gasket to fix a few gaps.
The Devil is in the Details !
And I got this right. New handle …new keys… and a lucky key chain. I almost forgot the plate holder for the back.. So I did the restore on it and ….
Looks great! This plate holder came off the Colman tent trailer that is donating many things to the boler. I should turn my attention to the inside flooring.. There’s work to do in there.
I’ve filled the holes in the floor and used the latex caulking on the seams of the interior cushy wall cover.. And with help I got the front and rear windows in.
The lock strip was the hardest part of this.. But got-R- done . Just a few more things before installing the flooring.
Like this fresh water fill. And the power cord hatch.. and the sink drain connection.
Of which I think I better label so no one hooks water up to it.. That would be messy. This is for hooking a hose up.. and draining into a bucket.. or your friends tent.. or use your own ideas..
Had a bit of a fight with the glue that was recommended by the flooring store.. Ended up mostly using contact cement. ( they said do not use contact cement) but it works great.. so not sure why I wouldn’t use that .. given the fact that there is all these weird surfaces. However ! It looks great.. and should be easy to clean.
Work on the boler will have to take a bit of a break for a few months.. There is a strong possibility that we will be moving.. so I have to clean out the shop for viewing. And that was just the kick I needed to get the trailer to lock up.. and back on the frame..
Got a lot more done today.. and this is what it looks like now.. still need the frame under it.. but that’s happening tomorrow.
Body Meets Frame !
And it’s a perfect fit !
We put foam canopy tape on the frame… everywhere it touches. Bolted down with galvanized bolts.. So it could be lifted off again. And those are not through the frame.. beside the frame.
And this is all you see.. inside the cabinets. Way better..
And the rear bumper is a perfect fit ..with the spare tire close .. but not touching the back of the trailer. Now I’m wiring the running lights so it can be towed around.. Oh and I have naked 12 ” rims on to keep the trailer low.. so it fits through my 7 ft high door. It will end up being 4 ” higher with the proper wheels.
Lights ! Camera ! just a bit of Action !
Pretty lights.. Yup got this part done… and then it was out the door..
With the 12″ rims only ..the trailer fit nicely out the door.. and then the real wheels went on.. and I towed it over to the other driveway..
But not before a photo op.. I like the ride height.. So it’s tarped to keep the weather off, and all the bits and pieces are inside..
The next page will happen when I get back to doing the interior..
I have chosen to go with paint that I’m very familiar with. Paint that works good on fiberglass.. I can roll it or brush it and it’s very glossy.
Yes it’s boat paint! How fitting for the boler. A few years back I chose this paint for the Bazooo 6×6 . Because the body was fiberglass. This time I have the sand-able primer too..
And here’s the primer on. Took most of the quart.. so now I’ll have a good idea how much two finish coats will take. This primer is great at covering everything. I found a few holes I missed ..so I’ll fill those and touch up the primer. Needs 24 hours drying time and then a fine sanding.
The front of the trailer looks like new ! Tomorrow I’m going to apply the first coat on the top half.. Off white.
Very little difference in the off white from the pure white. And that’s good.. cause I want it to still look white. And shiny too ! Tonight I’ll put the first coat of beige on the bottom.
But there was a debate for the bottom color.. I was favoring blue… but the person who will use the boler liked the beige. She wins and now I like it too.
Ya. it’s kinda retro looking.. And classy too.
Soon I will have the second coat on the bottom.. then I’ll bring the door inside and paint it.
And while the paint cures…. I’m thinking of the lighting… Ya the electrical will be covered in a new posting ..further along. But I have finally collected all the lights.
Ta Da.. All are LED’s ! and things of beauty.. Those 7 ” tail lights are hard to come by. The interior lights all have the switches on them.. We all know that LED’s in your home save money… in a RV they save your battery. Back to the paint thing….
I’ve actually got the painting on the body done before new years. And I’m super pleased with how it turned out. I went back to using a foam roller for the last coat of Beige bottom paint.. And wow nice and smooth. I’ll buy more foam rollers for the cabinets. The door is primed and ready for the off white.
And here is the second coat of finish on the inside of the door. Looks like it just came from the factory. Once this is done both sides then I plan to install the roof vent and the door.. and wheel the body outside ..still on the dolly. This will make room in the shop for the interior parts to be repaired and painted.
Here’s the vent all cleaned up and ready to install. PROPERLY with butyl tape.. not silicone. And no rivets.. I’ll be using Stainless Steel screws.
Change of plans.. I now have Dave here to help with attaching things. Need a person on the inside and on the outside. So I would like to finish to the point where the body is sealed ( won’t leak ) and put it back on the frame too.. Because when it goes out it’s gonna get cold.. So the boler will be complete except for the interior cabinets. And for this next step I will start a new page..
Here’s the post for that stuff.. My mind just goes crazy with what I can do.. And aside from replacing the missing cabinets, There is way more I’m thinking about.. Everything from adding lights and vents.. to redecorating the kitchen ! I could turn this camper into a very nice place to spend time..
I was at the building supply store getting a tarp.. While there I had a look at the formica laminate samples. So let’s start with some décor ideas shall we. Brought a bunch home and looked at them with a door, a cushion and piece of paneling. And these samples jumped out..
And this photo is not a good one for the true colors. So I went out to the camper to look again..
I put the laminate sample on the table .. and .. wow.. yes that works.. WAY classier than the white. And the same goes for the kitchen counter top.. And that little swatch of yellow.. It’s a close match for the Harvest gold sink and stove that will go in the boler. When I see it next to the oak cabinets and the new counter top I like it a lot.. That’s a solution to the partially painted walls in the kitchen..
Yes ! it is. I’m thinking this color is perfect for all the walls and the cupboard fronts in the kitchen.. only.. maybe. Plans change. But I got a liter of the paint to try on one of the boler cabinet doors..
This larger sample gives a better idea of the look. It’s a very nice “earthy” warm yellow. The black & stainless steel appliances will look good. I need to find some lino for the floor that is light color and ties it all in.
Now for some changes… Functional changes. The Hood over the stove.. looks like this..
Someone wrapped the front in polished aluminum.. ok.. I get it .. but moving the switches over to the monitor panel..? And using the water pump switch as one of them.. naw. not for me. And! do you notice something missing from the monitor panel ? YA all the labels telling you what is what.. Soooo I’m changing the whole shaboo.. for the hood from Dave’s old wrecked Award trailer.. It’s got the monitor panel and clearly marked switches right up front..
Nice eh ! There is however too many lights and switches.. I’m not sure yet if the camper has two holding tanks or one.. and the fresh water tank I’m getting from Dave has no level sensors on it.. That could be fixed if I can find a source for them. And the battery level ? With only three lights ! Well you all should know by now that I prefer the digital one. I’ll do a bit of modifying to suit my needs . And paint it black too.. All appliances will be black. I’m thinking of swapping out the range for the one from Dave’s Award parts trailer.. It’s a newer stove with a piezo lighter and it’s a nice black finish too. With a stainless cover for the burners. Nice! I had a look in the dump valve box .. found a few things I thought were missing.. and could plainly see that this camper has a grey tank and a black tank.. So the monitor panel makes sense now. I will just need to figure out which wires read which level. The Bigfoot was moved to storage at a friends place for the summer.. His place flooded this year .. and the river was about 6 inches up the belly of the camper… So some water got in the door.. It seems ok though.. other than some silt nothing bad happened.
Sept 2018:
It was time to bring the Bigfoot home for the winter.. The nice stands were available now that the Frontier was on the trailer.
I gave it a bath …and it’s looking great. This is a good place for it to spend the winter.. and in the spring this is a good place to work on it too.
Yup.. I couldn’t resist.. it’s just the way I am.. But I’m a bit fussy as to what I take home. These are some of the most desirable truck camper out there.. And still being made.. Here in the Okanagan. Two piece fiberglass construction. They are not prone to leaks.. or rot like the wood frame ones. Plus they are better in the cold weather. Because if this they hold their value. So when I was offered one (that needs some love) at a low price that allows for money to be spent ..I jumped on it..
The truck it was sitting on got sold early this fall.. so there it sat on the jacks. This is the same place the boler came from.. But doesn’t need the same amount of work.. It’s just the interior that needs help.. Exterior just needs a bath.
Yes I now have 2 Campers !
The Frontier camper is almost ready to go use.. very little work needed. This however is a bit more of a project.. And it’s not just a good cleaning. So next spring we will use the Frontier and enjoy it. When I get this camper all done we may want to use it instead and sell the Frontier. We’ll see.
For now I brought it home and we will keep it on the trailer for the winter. This is a big camper.. 11 1/2 ft ! and heavy. Still no problem for my truck. Bigger means it’s roomier inside.. a full bath with shower.. large dinette. and a good size kitchen. The bed is a full queen too. There’s an awning on the side.. Frontier has one too.. Basically this camper has all the stuff you would expect to have in any RV. All nestled on the back of my truck. Turns the truck into a small motor home.
The good …the bad.. and the work.
I made this comparison photo.. to show how messed up the interior is
Yup.. it looks bad for me .. but I’m not afraid of a bit of wood work. The table and the cushions are there.. and in very good condition.. I’m actually able to tweak things a bit.. But I like the way it’s laid out and will copy it closely. Same with the kitchen cupboards..
There’s a bit missing here too.. Again I do see this as an opportunity to change the counter top.. and add a cupboard to the bottom. Because some of the paneling is missing.. I’m tempted to do a bit of painting .. Also the floor has been added to for more stiffness.. so new flooring is in order too. I could make this camper real classy.. Here’s a photo from the web of what the kitchen looked like from the factory with just a few personal touches.
They did a nice back splash ! Let’s see how I do.. So many possibilities.. It’s going to be nice to do this kind of work.. no wheels , no motors..
And what about the LOU ?
It’s called a wet bath. And needs a good cleaning.. but not much else. so long as everything works. However look at the sink.. it’s hiding under a piece of foam? Not for long. I’m sure there are some repairs needed here and there.. I’m making a list of parts needed. It’s just things like drawer slides.. better ones. New LED lights, I’m going to replace both faucets as well..
Venting.. It’s a problem with the older Bigfoot’s. Of coarse the windows open.. but you can’t leave them open cause rain can get in. The only roof vents are the bathroom one and the escape one over the bed. Again you can’t leave them open. The bath one is inside that tiny room anyway. So I will need to install a roof vent in the middle that will have a vent cover. I’m thinking of building a winter cover for use on the escape hatch.. so it too could be left open without worry.
Leaks ! I found two leaks.. One is where the awning is bolted to the side of the camper.. A little bit of water from the snow melting on the roof is running down the side and finding it’s way inside. The other was dampness on the top of the propane cabinet.. I could see that the caulking outside on the top of the door was pulled away from the wall.. I fixed that. Now let’s not be too worried about these leaks.. because there is no framing in the walls.. just foam and the fiberglass shell.. but it does effect the wall finish.. So.. I’m going to have to tarp the camper for the winter.. And we are going to put an electric heater inside to help dry things out..
I have chosen a power vent to install on the Bigfoot. and included it in a rather large RV parts order..
This is a new product and it has great reviews. It has it’s own rain cover ! so you don’t need to buy a separate cover. A 4 speed fan that only vents.. but that’s ok.. it’s all that is needed.. and the price is great too. I also was thinking of how to keep the water off the windows.. These campers don’t have gutters.. the water or melting snow .. just runs off where ever.. cause the roof is curved. They make drip guards for doors.. and you can buy them in any length. So why not install them over the windows ? Yes!
And I thought perhaps it’s time to make a video….
Today I also when to my friend Dave’s RV graveyard.. to see what could be used for the Bigfoot.. Lots of great stuff.. Some of the cupboard doors, paneling.. and the hood vent ..
I’m now going to tarp the Bigfoot for the winter.. and not venture out there much.. I said that about the Frontier camper too… but could not help myself.. I was in there lots thinking about what I’m going to do. So I’m sure the same will apply to the Bigfoot.. Yup I’m very sure. And on that note it’s time to start a new page / post for all my ideas.. fixing , changing, and even the décor..
These are (interesting to me) rare things that I have found :
Some I have fixed up and passed on .. and a few I still have stored. Now someone may argue that some of these things are not really that rare . But if it’s uncommon for the average Joe to own them.. So here I is list them. I’m going to start with the tractors / mowers .. these were my hobby for a long time. Many of these were documented in my old blog. But now I’ve lost that because I wasn’t using it enough when I got my own domain with a new blog.. The one you are reading now.
This is a GE electric lawn tractor.. I went almost to Edmonton to get this from a farmer.. I never got it running and flipped it for more dollars.. to a collector of these rare tractors.. yes they are hard to find.
Here’s it’s big brother ( bigger motor) no mower deck, that was lost.. I found this one locally.. And I still have it .. Very rare.
This is a Toro Groundsmaster.. A very serious mower.. with a large deck.. I had two ! and I still have the parts one waiting for me under a tarp.. needs a lot of work.. maybe not very rare but still hard to find..
Oh yes.. a very rare Struck mini dozer.. So cool.. got it running great. works just like a big one.. but the size of a lawn mower. 8 hp. I found this way up Kootenay Lake.. sold it.. I have a video
Rv’s that are unique.. and a bit on the rare side..
My 1977 classic GMC motorhome. Hard to find a good one in Canada.. I used it two seasons and sold it for a profit.. they gain in value if you keep them nice. I went back to pulling a trailer.
Our 94 Award 27 ft trailer.. Loved this trailer.. used it for many years.. but it started to have structure problems.. so we sold it cheap.
1986 Winnebago LeSharo motor home. Not very common.. cause they always broke down.. French motor ! I have replaced the motor in this one .. But it runs like crap. Sold it cheap as is… It’s story HERE
Let’s included the Boler Trailers !
# 1.. 1974 Boler.. Fully restored by me in the winter of 2017-18. Now lives in Edmonton. See the Blog post HERE
#2 1979 Acorn/Scamp, currently in the shop and having a new floor installed. I’ll update the photo when it’s done.. /you can see the blog post HERE
ATV’s.. These are fun projects..
Early 1970’s 6×6 BAZOOO ! yes that’s correct spelling. I fully restored this one winter.. and It ran good.. But I just couldn’t see myself keeping it. I sold it to a collector of rare 6×6’s .. it now lives in a museum in Indiana. full story HERE
A rare 1974 Terra Jet. 4×4 amphibious ATV.. yup it floats ! It’s unfinished and stored for now.. I need to install a motor. and do the body work.. Full story HERE
Then there was a boat..
Very rare indeed.. 1959 Perfomer Seven Seas .. I got about half way done and decided I would never get to finishing it .. so I sold it to a fella who will.. I’m keeping in touch with hi, and hope to see how he does.. Full story HERE
Here it is.. in the shop. The dolly I made worked great. Rolled right in.. Now we’ll let it thaw out a day or so.. It snowed and it’s cold out.
Naked Boler !
All the windows and lights.. and everything has been stripped off the body and now I’m sanding and repairing. I tried using paint stripper on the pool paint.. Nope not working.. the sander is the only way that crap is coming off. This is going to take a week or so.. I hooked the shop vac up to the sander ..so I’ll have less dust.
About half done now.. and found some more ouchies.. But there were fixed properly.
God only knows how you can do this to a nice little trailer.. but there you have it. There’s repaired damage to the left front lower corner too. Most likely a jack knife situation..
Here you can see the difference the sanding is making. I have finished sanding the top half of the body. I’m in the process of filling the unwanted holes and the repairs. Here’s a new video…
The crack repair turned out good.
I put a coat of primer on to make sure . It should never crack again. Because I will have the supports for the upper cabinet. Now to start the bottom half.. less fun cause it’s down low..
I started at the back.. and by fixing the bottom edge. It was jagged and uneven.. so I trimmed a bit off.. Looks good now.. This process needs to be done all around the bottom.. Plus! the paint was harder to remove on the bottom half. I’m using a big sander with 80 grit to get the pool paint off.. then finishing up with the small sander.. which I need to fix now.. I need a part so I’ll clean up and work on the door..
Here’s all the bits and pieces.. nothing to fix here. The door worked ok.. even locked. So just the hinge pins and the inside and outside handles are replaced. And as for the door !
There you go.. it’s in great condition.
Nov 19 2017:
I had to go to Kelowna ..so I paid a visit to the fastener store and picked up the stainless steel bolts and screws I would need. I also picked up a metal polishing kit.. and couldn’t wait to try it out.
Wow.. with a bit of work I now have very shiny hinges. I did them all.. cause I can ! Here’s the latest video I made ..
Dec 10 th 2017:
Progress has been a bit slow as of late.. lots of distractions. Also sanding the hard pool paint off is an exercise in patience. I’m getting there but it’s going slow.. and some days I just don’t want to do it at all.. Today I’ll make a good effort. Determined to get the last of it off the bottom of the boler. Then there are a few holes to fill.. a final sanding and I can start with the painting.
This is some of the work I’m doing on the front of the trailer. I had to reconstruct the opening for the frame. It was in the wrong place.. and I want the front to look proper.. no holes all over. There was also chunks missing out of the bottom.. So I’ve got that all rebuilt with layers of fiberglass.. and a bit of filler. Now the bottom edge of the trailer is uniform and smooth.
Here’s the same area with primer on it. I’m cleaning up the shop and the trailer to get ready for the painting.. I’ll start another post for the painting…
I was atending an estate sale at a rural property and just looking at stuff.. The camper in the shed caught my eye, and the wheels in my head were turning. I had thought about a camper when I was hunting with my friend Dave and his Brother this fall. Truck campers are better on the rough roads.. These are places I would never take our fifth wheel. And these are the roads that take you to some very beautiful camping spots. Free ones ! So the thought of having one just for those weekend getaways, camping / atving trips would be great.
Meanwhile back at the farm…..
Hiding in the shed.. this camper has been kept dry and safe for many years. So I had a closer look.. And it was in great condition for it’s age. So I made a low offer and they said sure.. need it gone the property was sold and everything needed to go.. So now I own a camper ! While I was there a friend from the ATV club came and said ” that’s good deal” and I’ll help you get it out of there and home.. Little did he know how long that was going to take. Well it took five hours to load it up..
Because of the low roof.. and me not really wanting to take the canopy off the truck.. I went and got the “landscape” trailer. The deck was low so not much jacking / lifting needed. .. However we had to extend one jack out because the trailer is wider than a truck. Soooo like I said ..long time but I got it home before dark.
Frontier Camper
Look a new Scooby !
Dave’s old hunting rig was a camper on an old trailer frame so it could be towed.. They called it “Scooby” . A lot of dust blew off on the way home from the years in the shed, but not enough. Other than a good bath.. there is only a few things to fix. And if I’m gonna have a camper this one ticks a lot of boxes for me. A bathroom YES, hot water tank, upper bed with headroom, no leaks, bonus canopy on the side… and it appears to have been looked after not trashed like some campers I’ve seen… Plus it was stored properly so I can assume that everything works. 9 1/2 ft is the perfect size too. I would just need a short hitch extension to tow my quad on the utility trailer.
None of the lights are broken.. one jack leaks, but works.. My friend that helped me gave me two spares. The two 20 lb propane tanks are old .. and there’s a crack in the right front window .. All easy fixes. They could not find the keys.. so I’ll have to change the dead bolt.. The staining you can see on the right rear corner is from the leaky jack. Degreaser will take care of that. The decals and stripes are like new ! It says the weight is 909 kgs. That’s 2000 lbs, no problem for my truck.
Nov 5 th 2017: Interior Tour…
Well what does it look like in a early eighties camper.. BROWN ! Lots of it.. and wood too.
If your into wood and brown carpet.. then this is your place. I kinda like the retro feel .. just not the carpet.. I think it’s a bad idea in any RV.. But there is lino under the carpet.. and yes it’s brown too. Still better than carpet.
At least the counters and curtains are white. That fridge is in perfect condition.
Nice stove with an oven.. They don’t make a four burner anymore. please excuse the dead flies. I’m not cleaning it till spring.
And gadgets ! Who doesn’t like gadgets ? I’ll be moving the thermostat over a bit to make room for more gadgets. And that wallpaper is very familiar.. Fugly but familiar. I can live with it.
That’s a bunk above the dinette.. that’s also a good cupboard when the bunk is closed .. cool idea. There is lots of storage in the camper..
And how about a nice sink.. with a hand pump ? What for.. there’s power and a pump.. AND I found a battery! I was thinking this old of camper would use a second truck battery. Nope. Has it’s own. Bonus! And just like any good RV when you plug in to 110 v it charges the battery. But not the one I found.. very old and very dead.
Lots of room up top.. and a very good ” proper” mattress. Nice size opening windows for that important breeze in the hot months.
And no tour would be complete without a peek at the LOU. A bit tight but all campers are. No shower in this one.. Never use it anyway. But having a toilet in the middle of the night is a blessing.
Beddy Bye Time…
Today was cold but dry. and I got the chance to tarp the camper for the winter. But before I did that I could not resist running power to the camper and see if it has life. You bet it does ! only two burnt out lights.. I could hear the inverter working it’s magic. And I tested the pump.. But I did not try the fridge because I wasn’t sure how to turn it on ? Oh well in the spring I’ll go through all the stuff.. For now I’m making up some blocking for it’s winter resting place… so Dave can have his trailer back.. No Scooby.
Plans for the spring:
Can’t help myself.. gotta think about my mods and repairs. The roof needs to be resealed.. that’s a given. This camper shows no sign of leaks and I’m keeping it that way. Since the one piece aluminum roof has been ( for the most part) kept out of the weather. I’ll presume it’s still got all of it’s integrity. Looks like the vent lids were replaced at some point. But the two plumbing vent caps are crispy critters. And the big escape hatch lid is showing signs of it’s age too. So a parts order will include those. Plus as always I will install vent covers on the three vents. The fridge vent is metal and still good. The only other concern is the two front windows. I know one has a crack so it needs a fix.. I’m thinking I’ll remove both and have new tinted glass installed, then reseal them. That should keep mother nature at bay. Now for the “could live without.. but I want it anyway” stuff..
This is the panel I made for our fifth wheel. I won’t bother with the stereo.. but the other gadgets are very handy. A 12v power outlet, a dual USB charging port, a digital volt meter and a switch to turn them off. The kind of camping that I’ll be doing is far from power, so knowing the battery level is important. Charging my phone is too.. even though I’ll be far from service.. It’s my camera. Changing the lights to LED will save power too. so that will be done.
Nov 6 th 2017: Today I moved things around ..BOLER into shop, and the camper into position where it will stay for the winter. I thought I’d replace the leaking jack.. the oily corner of the camper was bugging me.
Not any more.. I wasn’t going to mount the clean jack to a dirty camper.. so It now looks like this. Nice! Tomorrow I make some horses to hold the camper.
Hate those Camper steps !
With a passion.. so my brain went to work and I thought of this idea. I see it on new campers.. regular RV folding steps.
So I got on Paint and put my thoughts to paper.. well screen. A light weight platform and folding steps. Why not ! Gives a place for a tool box … and a railing / handle. We need these things as we get older. Those accordion style steps are killers.
And That’s That:
All put away for the winter. Will start a new post in the spring..
But I can’t resist doing a few small jobs. Like the hot water tank cover was very rusty ..and that bugged me like the jack.
See.. It’s nasty looking.. when the rest of the camper is not that way. SOOO.
I made it all pretty again.. close match color too ! I have an order coming for RV stuff.. The vent covers, new interior switches, LED lights and little bits needed to make the camper perfect..
Nov 22 2017:
All my parts came. And I stashed them in the camper. Who knows I may feel like doing some of that work before spring. Just not the roof stuff. Yesterday I was showing the camper to my friend Dave.. so we plugged the power in and tried a few things.. Also turned on the propane and lit the stove.. and fired up the furnace and fridge. All is in good working order.. I switched the fridge over to electric and left it overnight to see just how good.. The freezer was ice cold this morning. The furnace started to warm the camper up nicely too. Wow.. we have a winner.
Just couldn’t leave it alone…
So I made up the “panel” .. yes the one …or version of.. what I like to have in all my campers.. 12 volt power.. USB ports.. and a nice easy to read volt meter.. All on a beautiful gold panel.. ..
And here’s the gadget center… installed but not hooked up to power yet. I’ll do that when I change the light.
Update: Summer 2018
When our fifth wheel came out of the RV port.. the Frontier camper went in.. and that was 4 months ago. Other than installing some LED lights and doing some cleaning ..it’s been left alone . When we moved it I use my truck. It was realized that this camper is just a little bit too wide for the tailgate opening of the truck. So I’ve come up with the idea of making a new “Scooby” ( that’s a camper set on an old travel trailer frame) Like I mentioned earlier in this post. Now you can tow the camper ! I was given a free 18 ft trailer that was damaged and had leaked.
It’s been sitting for many years… So we stripped all the useful parts and wrecked it to the frame.
And that I brought home … with the floor still attached .. But we removed that too. It’s the perfect size for making a scooby. I have flat deck registration and a plate for it so we are set.
Here I’m working on the mods to the frame to make it camper friendly. The camper will sit 12 inches forward of the rear bumper.. so I’ve meshed in on either side of where the rear step will go. And I’ve added 13 inches out from the frame for fenders and to better fit the width of the camper. Plus a few more cross pieces to better hold the deck.
Here’s my right side fender.. all done even painted.. in fact I’ve painted most of the frame now..
A complete change of color.. Gloss black is the new choice. The wiring is done too..
With a new box , brake a way switch, but used good salvaged wire from the wrecked out trailer. I’m thinking I would like to start a new post for the continued work on this project..
Yesterday I started the process of lifting the body off the frame.. Not too hard to do… I’m working alone. Just need a floor jack and beams.. After taking out the rusty screws. It started raining heavily so I had to quit. Today I’m back at it…
Had to remove the wheels so I could lower the frame more to clear the wheel wells. So I put two 12 ft 4×4’s under the frame and pulled it out with the tractor.. All went well till I bumped one of the jack stands and the body almost fell to the ground.. But I sorted that out and .. the frame came out and the new wheels went on. One of the old wheels had a leak..
And there you have it… one SAD boler frame. Yes it’s light.. but it’s very flimsy too. Never mind the rust.. it’s cracked behind the left wheel…
Apparently this is common.. and it’s only one of the reasons why you want a new frame. Usually the tongue has broken too and someone fixed that.. wow
Look at that ! they even jammed a piece of wood in there.. Let’s just say that this was not a “road worthy” frame.. and build a new one. However first thing I want to do is construct a cradle for the body so it won’t have to sit on those jack stands any more.
Done! I built it to hold the floor and the two ends.. My wheels are a bit wimpy but it’s all I got .. and they should help when I need to move it into the shop.. Now I stare at the frame and wonder where to start. Some have built the new frame on top of the old one.. so as to get things aligned properly. One thing I need to figure out is just how different the suspension will be. The factory axles are Dexter Torflex. And still available.. but costly to ship. I bought the ones from Princess Auto.. made by the same company but they say 22 degree angle.. and the boler axle should be 10 degrees up and pointing forward.. A strange thing for sure.. but successful. However the old axle IS the same as the new one at 22degrees. Soooo I will flip the new ones ( they don’t say you can’t) and I will mount them an inch lower.. not much of a gain in height.. but still something.
Here’s the old and new.. for comparison.. The mounts are different ..but then the whole frame will be anyway.
One thing for sure ..this sag won’t be there ! That’s the new frame tube on top.. I’m kicking the old frame outside .. and cleaning up the new pieces.. everything is measured and the plans are drawn. Here’s the first frame video…
Well I did kick the old frame out and made a jig on my saw horses to build the new frame..
The debate still goes on which way to mount the axles.. I’m tending to favor the rear configuration.. it will lift the trailer by 4 inches.. but I’m thinking that’s good.. cause I saw damage to the old frame from hitting things. There was about 8 inches of clearance under the trailer.
Oct 22 2018: I’ve decided to have the arms up and leading the axle. And for a bit of extra height I’m adding a 1- 1/2 ” block between the frame and the axle. I should be within 1 – 2 inches of the factory height. This makes the door sill proper height.. you won’t need a step. And that’s the way boler’s should be.
I now have my four cross pieces welded in place .. That’s four more than the old frame had. The frame has been squared and corner braces added
The C – channel I used is from the Tent Trailer frame… light but strong. I’m cutting the tubes to build up the 6 ” drop for the floor pan. but since I’m working upside down it’s up…
I will cut the door opening after I have the frame braced. Oh.. and the old frame is no more.. I cut it up to use some of the better pieces. Would have been nice to keep it intact so I could show a side by side comparison.. but I don’t want to buy metal.. ya I’m a bit cheep. Re-use and Re -cycle.. that’s the way I roll.
It’s coming along nicely.. There’s the door opening. Used some bits from the old frame for this too. Lot’s of welding going on here..
Got to have a place for the propane tanks.. And a battery in front of that. Plus all this helps brace the frame. The down side is the weight.. I plan on weighing it when I’m done.. and I expect a few hundred pounds more. The up side is that this frame won’t need the body for support.. So the body is simply carried.
Here’s my new rear bumper.. it’s a work of art using pieces from the old frame. Also it’s longer to protect the width of the trailer. still needs a spare tire mount and the rear stabilizer jacks will be mounted too. I will make this slide into the frame and bolt in place. If I welded it that would make it harder to roll the frame under the body.
Oct 30 th 2017: It’s looking like I’ll finish the frame earlier then I thought. I got all the welding done.. cleaned up … and painted the bottom of the frame today..
Here’s the axles on.. and the two supports for the floor..
And now most of it is shiny black. I turned the heat up to dry the paint better too. Then I thought of a way to estimate the weight of the old frame. .. by weighing the bits. I estimate it to be 230 lbs. + / – 30 lbs. But at least I will know how much heavier the new frame is.
Nov 1 2017: Well I rolled the frame out of the shop.. parked it next to the body.. I’m so nervous thinking I got the sizes wrong.. But it looks like a fit . I want to take it and weigh it to see just how much heavier it ended up being.
And off to the scales and the landfill. And wouldn’t you know it ! Lighter than expected ! 330 lbs on the nose. That’s approximately 100 lbs more than the old rusty frame. Right on target.. I’ve still working on the rear bumper.. but the frame will stay outside now.. Like any good trailer.. :).
This summer a few of us were “talking projects”.. and what was worth the time and money. The boler trailer always topped the list. I said I should just do RV’s .. because I have lots of parts and a resource for new parts. Well I bought one.. cheap enough to spend some bucks on it. First I need to get the LeSharo RV running before starting on the boler. And then I park it till spring. but let’s get the blog going anyway.
And this is mine.. a bit of a mess. been stored for many many years. But it’s mostly there. It will likely need work on the frame first.. and then the body has way too many holes.. I plan to strip it down to the shell and start over.. The list of things to do is long.. however this trailer is still in good condition for it’s year. And so we begin.. with a video..
There’s a few things I forgot in the video.. like new suspension as well as wheels.. So it’s going to be like pulling a new trailer. Plus this is like a blank slate for colors and décor. We are already talking about those things.. And I’m thinking of ways to incorporate some of the parts I have. Also how to bring it up to date with things like LED lighting, power monitoring and better fabrics. All while trying to keep a bit of “nostalgic” ness to it. But the frame on these is always been the weak part. So if it’s never been replaced then you have to start there.
Frame: (problems under there)
How fortunate that there are lots of folks who have built new frames ..and shared their designs on the net. So I’m taking their ideas… and my ideas, and making a whole new frame. I’ll be using the main part of the Colman tent trailer frame that I was about to use for a new utility trailer.
This ( above photo) is a beefier frame 2″ x 3″ box steel compared to the factory boler frame 1-1/2″ x 2-1/2″ box steel. As well the bigger frame is bent not cut and welded to the angle for the hitch. I plan to add a third piece in the middle and have the hitch mounted to that.
I like this frame, mostly the body mounts. But I will add a few more pieces.. Adding a little weight here will not matter.. just means no problems down the road. The original boler design was to have a light frame and use the combination of a fiberglass / plywood sandwich floor to ADD strength to the frame. So they both need to be in good condition to work. Over time things would sag.. and weaken. And that’s the case with the frame under there now.
Yes I crawled under to see what’s up and shoot some photos. Above is the rear floor. And sure enough the left side has sagged. Someone welded a angle brace … but that’s not a fix. I’m surprised to see no other framing … just the two little beams.
And here’s the middle floor . ( where you stand and walk ) again it seams like no support.. That plywood / fiberglass is very strong ! It does not flex when I walk on it. And I really doubt that rusty bent piece of angle is doing much.
So looking toward the hitch it’s obvious that the frame was repaired. Long time ago judging by the rust. All these problems and the torsion suspension is very much wore out.. That’s why it came home on a trailer. I know I said I would not be starting this project for a while… but I’ve got a little spare time and just can’t leave it alone. I lifted the whole trailer off the ground.
Supporting it with my jack stands. Interestingly this took the sag out of the frame and show me that the whole back of the body was not tight to the frame anymore. Wow..
This is the floor under where the dinette cabinet was. The body is attached to the frame with these screws and washers. They were pulling out of the frame ! So when I lifted the rear they popped up.. This is NOT how I do things.. Those skinny little screws are most likely rusted and at some point would fail. That is why my frame will have mounting flanges and carriage bolts to mount the body.
Yes I had some fun removing stuff from the interior.
All the cabinets have to come out anyway.. They need repairs and will be repainted. May leave the closet alone.. it’s mounted very nicely with cap bolts. The rust that you see .. I believe was caused by moisture inside the trailer.. not leaks. If you close these fiberglass trailers up, then they condensate inside.. best to leave vents and windows open a bit.
Well everything is out.. Real easy to get at the mounting screws now. It can sit like this till I’m ready to tackle the frame. I got new suspension on sale.. so that’s another big part of the frame.
These will be joined with heavy angle iron before becoming part of the frame. For this blog I’m going to divide the work up into three more parts / pages. Most of my projects have more than one page ..cause I don’t like long posts. Next page will be the Frame. Then the Body.. and finally the Interior.
It was free… and you know how that goes.. It was also broken.. So.. time to make something different from the old girl. I’ve done it before.. made a nice useful trailer out of a old funky one.. I wish I took a photo of the Coleman before I took it apart.. But I forgot… So the photos start with a stripped down trailer (frame) ready for some decisions on what to make.
But let’s talk about why I took it apart !
Why not just fix it up.. nope. where do I start.. How about with the broken lift mechanism. We had to hook up our portable winch to pull on the four cables that lift the roof. The treaded block that is pulled along the crank rod was stripped. And it was easy to see why.. The roof was so heavy from water leaking in and soaking the foam and wood that even our 2000 lb winch needed help. so we went from corner to corner lifting and blocking … then taking up the slack with the winch .. till the roof was up. The roof was a mess.. and the canvas was ripped and things were just bad.. So I stripped the canvas off.. and removed the roof.. that darn thing must of weighed 1000 lbs ! It’s taken me two days to get the Coleman down to just a frame. A pile of aluminum, a pile of wood and a pile of steel. And I’ve gained a few parts.. stove, sink, furnace, power panel with 30 amp cord, roof vent, ice box and two sheets of plywood..
She was big as tent trailers go.. 11 ft long. with the fat 10″ wheels. and brakes ! All aluminum & steel.
What a great blank canvas for a trailer ! I will need to spend some money though. new tires / wheels so that I can use the one good one as a spare. Also a new 2″ hitch, and treated deck boards should finish it of nice. I plan to move the rear bumper in so that the deck is 11 ft long. That balances the trailer better. And I’ll trim the sides in flush with the wheels.. that makes the width exactly 6 ft. The plan is to build it similar to the tandem trailer I build and have been using for a few years now.
Love this trailer.. this has worked very good. But for the little guy I will do solid sides with stake pockets so you can add height. Oh and same height all the way around not raised in the front
For now I have to put this project aside to do other stuff.
Sept 9 2017:
Well I can’t work on the LeSharo till I get the motor hoist back.. So I got the new driveway done.. and now I’m thinking I’ll tackle the new trailer. I’m off to PA to get two new wheels for it.. I have new lights and a new 2 ” coupler.. so I can get to work.
I removed some of the crap .. like the propane tank holders, chains and the wiring . And today I stripped the frame of all the stuff that I don’t need …and some stuff I’ll change
Now I can pick it up.. so I put it up high on the saw horses. Oh and it’s upside down for a bit till I get a few things done. First thing is moving some of the cross pieces. One by one I’m spacing them out more evenly.
The brakes got put on this project .. when I bought a Boler project.. I will need the frame for that.. so.. nothing more to see here..
I saw this for sale cheap… and I was only sorta interested.. sorta !
So I threw it out there on the family page. I did so because many of them were looking at smaller RV’s. And this is the same size as a long pickup. but it has a lot of RV stuff in there. Including two full beds. So what to do ! I went and had a good look.. the motor runs but knocks so bad you don’t really want to drive it. The roof leaked at some time and damaged the ceiling panels.. But that’s not a big deal in this RV cause the frame is all steel. The rest is in good condition for it’s age. I paid the few hundred bucks and had it towed to Peter’s shop.. The plan is to explore the motor fix later this summer. Here’s a video ..
These Motorhomes have an endearing following:
And it’s easy to see why. The four cylinder motor gets very good gas mileage .. but is under powered for this size vehicle. It’s front wheel drive , therefor it’s low to the ground… No steps ! In fact it’s the lowest entry of any RV. The layout inside works very well.. and makes good use of the space. Here’s a new video that better shows that..
I made the forward bed down just to see how that went.. great bed. Also I wanted to see how much of a job the ceiling would be.. and it doesn’t look like that big of a deal. Looks like the factory ceiling was paneling covered with fuzzy headliner stuff.. Ok .. I get that.. but that headliner did not do well with the constant rubbing of peoples heads on it.. Plus it was glued to the paneling.. 30 years of rubbing , heat… cold.. nope . did not do good.. I’m thinking just smooth white finish is best.
Aug 2017:
I found a complete drive train for the LS.. running motor … not working transmission.. 33,000 miles on it AND it’s here in BC . just a 7 hr drive away..
Update: Aug 2017
After I sold the Empress motor home , I had the money to buy the motor from the fella down at the coast.. And how lucky I was that he was coming to Grand Forks to buy a car.. So he delivered the motor ( complete with transmission and front drive). What a great deal.. Even though there is a few years difference the motors are identical.
Also as a bit of bonus.. he discovered that the reason for his transmission not working was a broken wire connector. So I have a spare transmission too. I will also have both spare ECU’s for the trans & motor. I could just do a quick swap of the motors.. but I would like to clean up the new motor and replace some of the gaskets.. check the seals and set the valves.. All easier while outside the LS and in the shop.
Aug 10 2017: The LS is now in my driveway facing the shop door..
Today in the cool morning I have removed the front fascia and bumper.. and sizing things up.. wow there is a lot of hoses to keep track of.. Going to have to lift the front quiet a bit to get under there..
I have the new motor apart from the transmission now… sure don’t like the right side motor mount.. not enough room to swing a wrench. Seems every bolt holding the two together is a different length ! curse the French. And speaking of bolts ! are they metric.. or SAE.. seems a combination of both ?
I was using a 5/8 socket on the motor bolts .. so I’m confused a bit. So now to mount the motor to the stand and park the transaxle outside out of the way.
Sept 25 2017: I had lost the use of the motor hoist for a few weeks and while waiting I got some other things done.. Also needed the new gaskets for the good motor so got them ordered and here. This week is time to get R done. The goal was always to get the LaSharo running good before winter sets in.. and then I’ll park it till spring to work on the interior.
My nephew is a mechanic and he will come help with the swap.. He’s done many motor swaps. My next step is to pull the existing motor out .. get the two side by side and change over the best parts.. Then I want to power wash the motor compartment.
So after much cursing and sweat.. the motor is out and I washed the whole thing down. Nicer to work without all the yuck. Now the good motor needs a bit of work and then in it goes.
The old motor is probably re-buildable …or at least some of the bits are useable.. Need to get it on the motor stand and see…
Here’s the new motor in.. Took 4 hrs and lots of patience. And that’s just bolting it to the transmission ! now I need to hook up what seams like a hundred things. It better run… cause this is not an easy in / out sorta thing.
Oct 10 2017: Thanksgiving !
And I’m thankful that things are moving along with the re- hooking up of motor stuff.. I took a little break and went camping / quading with friends.. But this weekend I’m back at it scratching my head over the hose and wire puzzle. Got some great help from my Facebook LeSharo friends..
RUNS !
Yup .. it fired right up.. it’s now the 15 th of Oct.. and I have it all together and the coolant in there too.. I drove it next door and parked it for the winter.. SO will continue with renewed vigor in the spring.. Will start a new page for that.. And now I’ll focus my attention on the boler..
I’m going to spend another few days before I kick the TJ outside so I can use the shop for servicing tractors.. So let’s se what I can do.
The Chain :
There it is.. The greasy mess. Well this took most of a day.. got the tension sprocket in the wrong place. so had to do it all over.. Got it right now.. and everything is smooth. Also got the brake caliper mounted .. it fits it’s new home great..
Wheels & Rims:
today I was going to put the wheels back on the TJ.. But as I was looking them over and there was too much I didn’t like.. Two of the tires were very old.. like 40 years ! cracked.. They all had tubes in them.. .so there were other issues. I decided to pull them all off the rims. What a job.. rusted on there.. tubes stuck.. yuck. So what better time to pick the best rims.. clean them up … paint them and mount the new tires I bought two years ago.
This is the tires I got.. as close to the chevron tread as I could get with out breaking the bank.. Just need to go get them from storage. And I’ve painted the rims… black, BUT dark steel gray on the outside.. where you see.. classy.
When the paint is good and cured I’ll mount the new tires. Hopping the bead seals and holds air ..
Rollin Rollin Rollin…
Those are some bad tires .. but they hold air the way they are suppose too.. and they look good ..
I’m putting the body back on and covering the TJ outside for a bit..
But come on… gota take a photo first. And just because the TJ goes out of the shop.. does not mean I stop working on the project. I need to get the motor ready, The seat ready, the floor panels, roll bar and windshield.. All these things can be done in the shop still. Sooo lets start another page for the continuing work:
And that calls for some new parts ! Bushings & seals for the steering rod. And new seals for the axle bearings. That should keep the water out. And those new bushings will take the slop out of the steering.
Speaking of that.. I got the steering back in the TJ.. I amaze myself sometimes .. I got the bracket perfect.. Everything lined up. My backer plates are working good.. helps to squeeze the tub flat and get a better seal.
The wheel is nice and sturdy too. All the steering components are from the 76 TJ.. So other bits needed to migrate with them..
Like the brake pedal.. and with it came the parking brake. That will be nice to have.. And if anyone is asking.. I’m not painting inside the greasy chain run.. to much work.. and it’s protected with the grease.
I’ve been painting the front hubs.. and some other bits.. Got the bearings and seals in the holders ready to go.. Also cleaned up and resealed the chain cover on the transmission.
Just basically getting all the parts ready for re- assembly. I want a rolling unit by the end of month.. Because I need the shop to earn some money servicing tractors. But I’m not letting that prevent me from being careful and paying attention to the little things. Like…
welding washers on the control rods, for better action.
Today we got the axles front and rear back in. A bit of pushing for the rear one to get it through the transmission and the other obstacles.
The front was easy.. and as you can see the steering is all done. Just need the rear hubs back on and the wheels could be put back too.. and we roll ! But I’m a bit ahead .. so I’d like to install the chain and maybe the brake.
Things are lining up good.. But I need to cut some of that motor mount away to get the brake disc on.. Also my rear transmission brace worked exactly as planed..
This is a hallmark in the restore.. enough of the TJ is done so it will roll on it’s own wheels. And I can now determine the best placement for the seat. However It’s time to start a new page for the finishing touches… ..
I used truck box liner finish on the first Terra Jet.. and I liked the results. It’s a rough finish.. but hey it’s a rough looking tub.
And that’s done.. Reminds me of the first Terra Jet tub. ( below )
Yup.. more or less the same.. Except the frames are welded in the newer ones.. so much heavier to move. and while the Rhino liner paint is curing.. I set to work doing a few small touches to the bumpers.. plus I installed the side boards that protect the body sides.
Like this winch mount on the front.. It’s upside down .. so is the tub. This holds a 2000 lb winch quite nicely.
Also a small improvement to the hitch.. some places to hook to. Very nice.. It’s the little touches that I like.. Everything got some black paint.. and will be finished off when the tub gets flipped. I’m trying some new paint.. It’s much like the Por 15 that I like.. but less cost. So far so good ..
It’s a nice shiny black.. and brushes on smooth. I’m cleaning and sorting and painting some of the parts.. I’m finding out that between the two Terra Jets there are big differences.. Such as the steering. I noticed that the steering from the 76 TJ is offset to one side.. so all the bits are different from the 73 TJ where the steering wheel is in the middle. Hmm.. I have to be careful.
Even these pedals are slightly different.
One thing leads to another:
So I’m picking and choosing the parts I want to use.. And I’m finding all kinds of compatibility issues. I want to use one part of the steering from the newer TJ and that means I need to change a bunch of stuff.. and ! I will need to use all the steering parts from that TJ all the way to the wheel hubs.. On top of that ..
The brake pedal , and it’s hanger / cross piece are a bit different to allow for the steering shaft and the park brake to work..
And this bracket .. for the steering will need to move 2 ” over to the left. Because the new steering is offset to the left.. Geez ! I’m sorting it out..
Inside the tub:
Lots to do as soon as the paint cures good.. I will need to move that steering bracket, weld on a center seat support.. and a battery tray. Also I have to remove the transmission adjustment bracket. This setup is for a two stroke motor. It will be in the way of my bigger motor.
This will be changed to the newer style.
This is the new way.. the bracket goes.. to the back wall. This is also an adjustment for the clutch belt. And a mount for the clutch brake.. that stops the transmission for changing gears.
Got the inside all cleaned and the steering bracket moved.
The other unnecessary stuff removed.. Above you can see the body seam caulking .. A little added leak proofing.. and it smooth’s out the sharp edges for painting. Again I’m going with gray paint.. it’s easier to see leaks and to work on stuff with a lighter color.
PLUS… It looks good with the black tub.. blue body. Just need to install a battery holder and modify the motor mount to suit the Honda. And that leads to the Re- assembly . And another page !
