Shiny Shacks

In the 15 years I have been restoring Airstreams I perform floor replacement and frame repair with the shell on. I see the risk/benefit scale in favor of shell on work. Here is a description of how this is accomplished.

1) The old floor is removed along with all bolts and screws holding the floor down and perimeter channel to the floor. The belly pan is cleaned of old insulation and the ubiquitous mouse nests.

2) The frame is inspected and repaired, this may include the removal of damaged cross members and welding in of new ones. The frame is then coated with POR-15 Anti-Rust sealer.

3) The forward piece is placed in as a single piece. It is brought in at an angle and worked into alignment, this is accomplished as the curve of the forward dome allows for the piece to be maneuvered within the space. All subsequent floor segments will need to be installed in 2 pieces. I place the seam along the street side frame rail. This allows for each floor segment to be supported on all sides. The longer section is installed first, then the shorter segment is set into place. The placement and movement of segments should be done by a striking a piece of wood placed against the edge of the segment to avoid damaging it.

4) Marking were the frame rails and cross members are located assists in the placement of screws attaching the floor to the frame. I predrill hole with a 1/8" bit on a counter sink head. I then use self-tapping metal screws to attach the floor.

5) Fill any gaps and cover screwheads. Sand the floor to create a smooth surface for the installation of flooring material, Marmoleum preferred.

Another tip to the floor removal in Airstreams.
The elevator bolts holding the floor down are run through the cross members of the frame and bent over at the factory they will have to be cut off and ground down. To get to them the floor needs to be out of the way. To lift the floor cutting around the bolts allows for the wood to be lifted out of the way. A hole saw allows for a quick access for a Jigsaw blade for cutting sections of the floor.