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

Discussion in 'Build Threads' started by Dylan W., Nov 22, 2018.

  1. Dylan W.

    Dylan W. lone resident of Bro-Lite Island

    Joined:
    Mar 17, 2007
    Location:
    Mocksville NC
    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: Feb 10, 2019
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  2. Dylan W.

    Dylan W. lone resident of Bro-Lite Island

    Joined:
    Mar 17, 2007
    Location:
    Mocksville NC
    Oops..I made a mistake in the above post.
    It was not a Gibson guitar string..it was a Martin. 20190210_213909.jpg
     
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  3. Dylan W.

    Dylan W. lone resident of Bro-Lite Island

    Joined:
    Mar 17, 2007
    Location:
    Mocksville NC
    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: Feb 10, 2019
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  4. WARRIORWELDING

    WARRIORWELDING Owner opperator Of WarriorWelding LLC.

    Joined:
    Jan 6, 2008
    Location:
    Chillin, Hwy 64 Mocksville NC
    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.
     
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  5. Dylan W.

    Dylan W. lone resident of Bro-Lite Island

    Joined:
    Mar 17, 2007
    Location:
    Mocksville NC
    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: Feb 10, 2019
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  6. Dylan W.

    Dylan W. lone resident of Bro-Lite Island

    Joined:
    Mar 17, 2007
    Location:
    Mocksville NC
    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
     
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  7. Dylan W.

    Dylan W. lone resident of Bro-Lite Island

    Joined:
    Mar 17, 2007
    Location:
    Mocksville NC
    Cabinets up! Time to add the 4th ceiling panel. Glue, screw and braced once more. 20190207_185952.jpg
     
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  8. Dylan W.

    Dylan W. lone resident of Bro-Lite Island

    Joined:
    Mar 17, 2007
    Location:
    Mocksville NC
    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
     
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  9. WARRIORWELDING

    WARRIORWELDING Owner opperator Of WarriorWelding LLC.

    Joined:
    Jan 6, 2008
    Location:
    Chillin, Hwy 64 Mocksville NC
    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.
     
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  10. Dylan W.

    Dylan W. lone resident of Bro-Lite Island

    Joined:
    Mar 17, 2007
    Location:
    Mocksville NC
    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
     
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  11. Dylan W.

    Dylan W. lone resident of Bro-Lite Island

    Joined:
    Mar 17, 2007
    Location:
    Mocksville NC
    I thought of this...the center doohickey was to long and I didnt fool with trying to remove it. I think the drill bit worked out ok.:D
     
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  12. a_kelley

    a_kelley mechanical fixer

    Joined:
    Jan 26, 2010
    Location:
    Rutherfordton
    You are looking for a forstner bit if you want a flat bottom , square to surface, perfect round hole.
     
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  13. McCracken

    McCracken Lip Snatcher

    Joined:
    Jul 9, 2005
    Location:
    With your mom at a nice seafood dinner
    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.
     
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  14. paradisePWoffrd

    paradisePWoffrd Recovering Project Junkie

    Joined:
    Nov 5, 2005
    Location:
    Newton, NC
    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.
     
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  15. Dylan W.

    Dylan W. lone resident of Bro-Lite Island

    Joined:
    Mar 17, 2007
    Location:
    Mocksville NC
    Thanks I'll keep this in mind, but honestly, the screw heads are small enough, the drill bit I'm using is making a plenty big hole.
     
  16. Dylan W.

    Dylan W. lone resident of Bro-Lite Island

    Joined:
    Mar 17, 2007
    Location:
    Mocksville NC
    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.
     
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  17. Dylan W.

    Dylan W. lone resident of Bro-Lite Island

    Joined:
    Mar 17, 2007
    Location:
    Mocksville NC
    Where could I find this?
     
  18. paradisePWoffrd

    paradisePWoffrd Recovering Project Junkie

    Joined:
    Nov 5, 2005
    Location:
    Newton, NC
    When do you need it? I can probly round some up and send it to ya.
     
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  19. R Q

    R Q Well-Known Member

    Joined:
    Apr 4, 2005
    Location:
    Charlotte
    Maybe try a wire PVC pipe cutter https://www.amazon.com/General-Tool...t=&hvlocphy=9009988&hvtargid=pla-420978968769
     
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  20. McCracken

    McCracken Lip Snatcher

    Joined:
    Jul 9, 2005
    Location:
    With your mom at a nice seafood dinner
    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.
     
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  21. rockcity

    rockcity everyday is a chance to get better

    Joined:
    Apr 10, 2005
    Location:
    Greenville, NC

    Use a survival wire saw. It’s a saw on a cable with handles on each end. Should work well for this if it’s long enough.
     
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  22. R Q

    R Q Well-Known Member

    Joined:
    Apr 4, 2005
    Location:
    Charlotte
    Sounds like a lamp cord! Strip the insulation, Plug it in and get busy! :D
     
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  23. Dylan W.

    Dylan W. lone resident of Bro-Lite Island

    Joined:
    Mar 17, 2007
    Location:
    Mocksville NC
    Anytime

    Itll be a little while before I have to deal with foam
     
  24. BRUISER

    BRUISER silent.. but deadly Moderator

    Joined:
    Mar 17, 2005
    Location:
    Raleigh
    I have used a turkey carving electric knife with a long blade.. worked great
     
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  25. a_kelley

    a_kelley mechanical fixer

    Joined:
    Jan 26, 2010
    Location:
    Rutherfordton
    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.
     
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