Pop-up to vintage standy (misc small stuff 5-13-19)

...ask your questions in the appropriate forums BUT document your build here...preferably in a single thread...dates for updates, are appreciated....

Re: Pop-up to vintage standy (air diffusers 3-5-19)

Postby aggie79 » Mon Mar 11, 2019 1:51 pm

I am really enjoying your build! Quite impressive. Thank you for taking time to photo-document your work.

les45 wrote:
MatHanz wrote:Nice work so far! I may have missed it, but what are you going to use to skin it? Aluminum?


I'm still trying to locate a source for the skins. I plan to use the standard RV type aluminum corrugated panels with the interlocking edges. There is a source near me just outside Atlanta and another on the west coast. I'm trying to figure the best price comparing shipping to picking it up myself. The metal skins will be on the sides and ends and I plan to use EPDM for the roof. I am currently paneling the inside and outside with the 5 mm Revolution plywood. I used that on the portable wall panels on my last project and it is some good stuff. It's primered on one side and very easy to work.


I don't know how current this article is, but it lists some sources for vintage RV aluminum siding. It also has a tutorial for DIY aluminum siding using coil stock:

https://nationalserroscotty.org/resources/siding.html.

Here's another link to DIY PDF: http://www.freewebs.com/kc8jwa/Lensidingfinal.pdf.
Tom (& Linda)
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Re: Pop-up to vintage standy (air diffusers 3-5-19)

Postby les45 » Tue Mar 12, 2019 6:04 am

aggie79 wrote:I am really enjoying your build! Quite impressive. Thank you for taking time to photo-document your work.


I don't know how current this article is, but it lists some sources for vintage RV aluminum siding. It also has a tutorial for DIY aluminum siding using coil stock:

https://nationalserroscotty.org/resources/siding.html.

Here's another link to DIY PDF: http://www.freewebs.com/kc8jwa/Lensidingfinal.pdf.


Thanks, Tom. I'm researching three of the companies on that list. I want to keep the corrugated look similar to what came on the original pop-up and it gets a little complicated with the numerous sizes, patterns, and types of connectors. Their web sites aren't really clear on some of those features so I'm having to talk directly to their sales reps to figure it all out. I hope to order something soon since all my outside work depends on the sheet metal.
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Re: Pop-up to vintage standy (interior done 3-23-19)

Postby les45 » Sat Mar 23, 2019 1:23 pm

I'm actually building this project from the inside out so I decided to go ahead and finish the interior before starting on the outside skins. Just like building a house, the interior trim is always the slowest and most tedious of the work. With some decorating input from my wife, we finally have the interior where we want it or at least 99%.

Front end with two person dinette and small galley cabinet. Lots of shelves and hooks. The bead board at the top is screwed in place for easy removal and access to the clearance light wiring.
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Better view of the galley cabinet and drop floor. The lantern is actually an LED light that I picked up for $5.00 on sale at a local discount store. The triple coat hook is Judy's idea.
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Different view of the front end showing the door and overhead light. The dinette table created a little bit of a challenge when I tried to install it. Apparently, there was a slight difference in my new shelf and my old shelf so I had to raise the rear support on the table by about 1/4" to make it fit with the existing leg.
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Rear bed area. Again, lots of shelves. Note the LED reading light and old style incandescent overhead light. Empty window frames are installed just for looks. I'll wait until I get the skins on to finalize the windows.
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The metal trim for the drop floor was also a challenge but the aluminum was easy to file down to make all the corners fit together. The biggest problem I had with the metal trim was finding the pewter nails to match since Home Depot didn't have enough. Turned out Lowes had them too.
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A different view of the left side showing the bed area.
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I'm still in the process of finding the metal skins so I can't finalize the side wall framing until I actually have the metal in hand. I fully expect to have to add some horizontal framing for stapling the metal panels. In the meantime I plan to go ahead and insulate the roof and install the plywood paneling. That will be another challenge trying to reach the center areas with the tight head space inside the garage. Stay tuned.........................
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Re: Pop-up to vintage standy (interior done 3-23-19)

Postby greygoos » Sat Mar 23, 2019 8:43 pm

Very nice and neat job. Happy camping
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Re: Pop-up to vintage standy (interior done 3-23-19)

Postby S. Heisley » Sun Mar 24, 2019 6:37 pm

Good Job! :applause:
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Re: Pop-up to vintage standy (roof insulated 3-26-19)

Postby les45 » Tue Mar 26, 2019 2:12 pm

Installed the insulation for the roof area today. I'm using 1.5" foam board since the spars are slightly wider than 1.5". Can't really insulate any of the other areas until I figure out my metal skins and any additional framing I'll need for them. Cutting the 1.5" foam with a box cutter was a little tedious but everything fit well with little waste.

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I'll be traveling for about 10 days so I won't be able to install the 5 mm plywood underlayment on the roof until I return. I plan to use an EPDM roofing material over the plywood. Hopefully I can get my metal skins figured out for the sidewalls soon and get them ordered.
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Re: Pop-up to vintage standy (bending trim 4-23-19)

Postby les45 » Tue Apr 23, 2019 12:54 pm

While I'm waiting on quotes for my skins, I've been playing with the metal corner trim to see how it will bend over a 7.5" radius on the top of the front wall. I cut some of the old trim from the original pop-up and bent it over the frame and was mildly surprised that it bent without any distortion and the vinyl inserts went in without any kinks. The sides fit flat to the frame on top and sidewall. All of the other bends in the trim are flat shallow angles so now I know that the rounded section will not be a problem.

side view of trim showing no distortion
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top view showing how vinyl insert fit nicely also
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Getting three quotes on the skins has become a little more complicated than I anticipated. There are so many variables of thickness, design pattern, lock joint types, colors, textures, etc. and each company has its own terminology and policies. I hope to firm up the skin purchase soon and they all say they fabricate and ship quickly. Hopefully I'll be doing something soon.
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Re: Pop-up to vintage standy (skins shipped 5-8-19)

Postby les45 » Wed May 08, 2019 3:05 pm

I finally ordered and received my aluminum siding. I decided to use The Metal Company of Arvada, Colorado even though I couldn't find too many reviews on their work. As it turned out, they were great. I asked for three quotes from The Metal Company and two other name brand companies in the RV siding business. The quotes came in at $1,100, $1,600, and $3,000 (quite a spread). I don't think the high quote really wanted my business as their shipping from their Georgia plant just 100 miles from me was $150 more than the other two from California and Colorado. Fabrication and shipping was super fast. The shipment came in on a Central Transport truck with tracking and the crate was 12' long by 2' wide by 1' high and weighed 230 lbs. The packaging was constructed like a tank and the quality of the siding was first class. I ordered 16" panels in a pattern to match my old pop-up siding (3" Mesa-1 with S-lock).

Shipping crate was outstanding with mostly 2X8 sides and 1/2" OSB top and bottom. I was able to salvage a whole box of drywall screws which made the un-crating very easy.
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Quality of the siding looks great. Matches my old siding exactly and no damage to any of the 23 panels.
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Internal packing was also outstanding. I removed enough craft paper and cardboard to fill two large leaf bags.
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I'm still piddling with some small stuff this week and then we will be traveling for a couple of weeks so I won't be able to start the siding until late May. I also received my EPDM roof material last week so I'll have to install that before I start on the siding. Hope to get most of this done before the heat sets in. Stay tuned.
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Re: Pop-up to vintage standy (misc small stuff 5-13-19)

Postby les45 » Mon May 13, 2019 12:12 pm

While I'm waiting to travel this week (Danube river cruise) I piddled with some small stuff that I wanted to get done. These included a small shelf at the foot of the bed to hold a laptop computer for watching DVD's on rainy nights, a storage box in the front area to store the propane camp stove, and a framework to hold the electrical inlet fittings.

We use an old laptop computer to watch DVD's on a rainy night so I decided to build a folding shelf at the foot of the bed. All the materials in this little project were simply scrap stuff laying around in my junk drawers. The 3/4" plywood was painted to match the existing paint scheme and is supported on a piano hinge with two chains. It is held in place when it's folded up by a bolt and plastic wing nut.
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When folded down the top of the shelf shows the same hammered silver Rustoleum paint that is used to trim out the rest of the cabin area.
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I installed an AC outlet under the shelf previously for the power cord. When watching the DVD's, we use headphones for better sound quality and less noise for our campground neighbors.
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Under the shelf area just forward of the dinette was a wasted space where the old pop-up winch and cable system used to be. I used scrap lumber to build a box for storing our propane camp stove. In the past, we had kept the camp stove stored in the garage and on our last camping trip we forgot to pack the stove. Luckily a good campground neighbor loaned us one. This will keep that from happening again.
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The box is made with a 1X2 framework (Kreg jig and pocket screws) and the 5 mm plywood and simply dropped into the hole and fastened to the framework with a couple of screws. It doesn't fill up the entire space so I used some more 5mm plywood to cover the remaining opening at the top.
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The bottom is simply a piece of the bead board used to trim out the cabin. I'll use a couple of pieces of foam to pad the stove and keep it from banging around when traveling.
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All I needed for the electrical inlet was a small piece of plywood mounted to the wood framing with a hole for the fixture to fit in. Note that the door on the left is one of the four air inlets for ventilation.
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The electrical inlet fixture is actually the water inlet from the old original pop-up that I cut and drilled for the Marinco 15 amp electrical inlet to fit. We used this on the previous project also. I'll wire it up later after I install my siding and I placed it in a location so that I can also reach it from inside the cabin near the electrical center under the left dinette seat.
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Off to Europe in a few days and will start on the EPDM roof when I return at the end of the month.
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