We Bought a RV Clark!! Oh no! Rebuild thread

So...with the curve in the roof line, I still have the problem of having square 2" thick foam but I wanted to try to come up with a way to add curve to my foam. I concocted a plan.

Plan is to use 2 of my custom curved wooded trusses, spaced just right, lay the square foam in my form. Then, using this torch..I'll heat this Gibson guitar string to red hot. Then, using voice grips, we'll be able to pull the string through the foam and create the curve.
20190206_151802.jpg


I thought it was a great idea, and it might be with another kind of string, but the guitar string failed. It just kept breaking. I guess it was the heat. I'll call this a good try..but a no go. Maybe a piano string?

Oh well, this show must go on. So I just added layer upon layer of thinly sliced foam. With the table saw, I was able to cut 6" inch wide pcs. Then, I simply adjusted my table saw width to whatever thickness I needed. 6" wide at a time, I was able to get a pretty solid roof full of foam. Glue was added to each layer..its thick and solid. At first, it was all goofy and uneven
20190206_180342.jpg

But after a few braces and an overnight smashing, it all turned out impressively flat. That's great, I like a flat sammich!
20190206_180316.jpg

Now were ready for the 3rd ceiling panel.
 
Last edited:
Using the tried and true glue it and screw it method, we had the 3rd ceiling panel up in no time. We added a few of those glue smashing braces and called it a night.

20190207_104226.jpg

20190207_104222.jpg


It's starting to take shape. Once these 3 panels are up, I can work on reinstalling the cabinets.

Note..the walls above the windows had no water damage. I was not about to replace all of this for no reason. It's kind of ugly, but the cabinets will hide all of this and I'm waaaay ok with it!
 
Last edited:
Your spelling is as bad as mine. But your wood and glue game is much stronger!:p

Is that paneling getting a coat of stain or paint?

Custom "cabinates" are in order for a build of this magnitude.
 
Of course the first cabinets removed from the rv, wound up being the bottom cabinets in the pile of cabinets in the storage building. Took a little while to untangle all the cabinet mess, but we were able to dig them out and get them hung in place. This is a cool milestone. I am in the beginning of the put it back together stage. At least for the front part of the rv anyway. The bedroom is another chapter.
20190207_113553.jpg
Gotta mettle through all these wires and get them where they belong..sort of.
20190207_113605.jpg
20190207_115004.jpg
20190207_151704.jpg
20190207_151712.jpg

The cabinets are back in place!

I wish they were a different color. I actually thought about painting them, but decided...screw that. They look good enough and I just dont want to add all that work. This rv ain't gonna be perfect looking. As long as its solid and smells nice, I'm good. So..ugly cabinets meet pretty walls and ceilings!
20190207_151704.jpg
 
Last edited:
WARRIORWELDING said:
Your spelling is as bad as mine. But your wood and glue game is much stronger!:p

Is that paneling getting a coat of stain or paint?

Custom "cabinates" are in order for a build of this magnitude.
Click to expand...

No custom cabinets! (Would be nice though)

I haven't proof read yet..what's spelled wrong?

The new paneling is all set. No paint or stain needed. Its showing up a little light in pics, but it has a little off white grain to it.


Edit!!! I fixed all the bad cabinets I could find..lolol
 
With all ceilings in place, it's time to add more trim to cover a lot of screws. Yay...alot more "hold yer breath" drilling.
20190207_200854.jpg
I had to get a few 4" wide trim pcs. These will cover the double rows of screws where each panel has it's own row.
I had to take a new vent out of the box so I could use the trim base to gauge where the trim should be cut to fit around it
20190207_222445.jpg
 
Screenshot_2019-02-10-22-47-48.png
Cut the centering do-hickey down some with a grinder and a good flush bottom hole.....or leave it if the extra depth want hurt.
 
I could drag this out a little longer, as there were a ton of different small things accomplished. I didnt take any pics of the wiring process or of the insulation process for panel 4 .With that said..I'm going to skip right to the final product!

Ladies and gents...my new finished ceiling!

20190208_203620.jpg

20190208_203629.jpg
20190208_123410.jpg
20190208_123420.jpg
 
Dylan W. said:
So...with the curve in the roof line, I still have the problem of having square 2" thick foam but I wanted to try to come up with a way to add curve to my foam. I concocted a plan.

Plan is to use 2 of my custom curved wooded trusses, spaced just right, lay the square foam in my form. Then, using this torch..I'll heat this Gibson guitar string to red hot. Then, using voice grips, we'll be able to pull the string through the foam and create the curve.View attachment 286017

I thought it was a great idea, and it might be with another kind of string, but the guitar string failed. It just kept breaking. I guess it was the heat. I'll call this a good try..but a no go. Maybe a piano string?
Click to expand...
That looks like what they do for houseboats / docks when cutting Styrofoam blocks. They usually use a car battery and a thicker wire like a coat hanger. You might try that if you're not too far along.
 
Dylan W. said:
So...with the curve in the roof line, I still have the problem of having square 2" thick foam but I wanted to try to come up with a way to add curve to my foam. I concocted a plan.

Plan is to use 2 of my custom curved wooded trusses, spaced just right, lay the square foam in my form. Then, using this torch..I'll heat this Gibson guitar string to red hot. Then, using voice grips, we'll be able to pull the string through the foam and create the curve.View attachment 286017

I thought it was a great idea, and it might be with another kind of string, but the guitar string failed. It just kept breaking. I guess it was the heat. I'll call this a good try..but a no go. Maybe a piano string?

Oh well, this show must go on. So I just added layer upon layer of thinly sliced foam. With the table saw, I was able to cut 6" inch wide pcs. Then, I simply adjusted my table saw width to whatever thickness I needed. 6" wide at a time, I was able to get a pretty solid roof full of foam. Glue was added to each layer..its thick and solid. At first, it was all goofy and unevenView attachment 286018
But after a few braces and an overnight smashing, it all turned out impressively flat. That's great, I like a flat sammich!
View attachment 286019
Now were ready for the 3rd ceiling panel.
Click to expand...

You likely dont have easy access to some, but the ripcord in most communications cables work great for this. Basically use it like a saw blade and it will go through foam/rubber like butter.
 
McCracken said:
That looks like what they do for houseboats / docks when cutting Styrofoam blocks. They usually use a car battery and a thicker wire like a coat hanger. You might try that if you're not too far along.
Click to expand...

I still have the back half of the rv to do.
Can you explain this process a little better?
Or..maybe I can Google it.
 
Dylan W. said:
So...with the curve in the roof line, I still have the problem of having square 2" thick foam but I wanted to try to come up with a way to add curve to my foam. I concocted a plan.

Plan is to use 2 of my custom curved wooded trusses, spaced just right, lay the square foam in my form. Then, using this torch..I'll heat this Gibson guitar string to red hot. Then, using voice grips, we'll be able to pull the string through the foam and create the curve.View attachment 286017

I thought it was a great idea, and it might be with another kind of string, but the guitar string failed. It just kept breaking. I guess it was the heat. I'll call this a good try..but a no go. Maybe a piano string?

Oh well, this show must go on. So I just added layer upon layer of thinly sliced foam. With the table saw, I was able to cut 6" inch wide pcs. Then, I simply adjusted my table saw width to whatever thickness I needed. 6" wide at a time, I was able to get a pretty solid roof full of foam. Glue was added to each layer..its thick and solid. At first, it was all goofy and unevenView attachment 286018
But after a few braces and an overnight smashing, it all turned out impressively flat. That's great, I like a flat sammich!
View attachment 286019
Now were ready for the 3rd ceiling panel.
Click to expand...
Maybe try a wire PVC pipe cutter https://www.amazon.com/General-Tool...t=&hvlocphy=9009988&hvtargid=pla-420978968769
 
Dylan W. said:
I still have the back half of the rv to do.
Can you explain this process a little better?
Or..maybe I can Google it.
Click to expand...
There's a lot of info out there on hot wire cutters. Some of it seems overkill for what you're trying to accomplish. It's just a wire with current ran through it till it heats up and cuts.
 
I have used a turkey carving electric knife with a long blade.. worked great
 
Look up hot wire foam cutter. Nichrome (toaster) wire and a constant voltage or current supply (don't remember which). I think hazard fraud may sell them. Also need a way to tension said wire.
 
Back
Top