1961 Shasta Areoflyte build for food trailer

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1961 Shasta Areoflyte build for food trailer

Postby R. W. Alexander » Sun May 12, 2019 4:31 pm

This is my 4th trailer build. My daughter and son-in-law were doing a weekend food business. I suggested a old retro trailer to attract the older crowd to their food set up. I started the build on February 15th. And I am almost done as of May 12th.
Attachments
IMG_20190219_105222582.jpg
The frame I had made. It has a 3500 lb drop axle on a 7 by 10 frame. Standard 2 by 3 inch, 1/8 inch wall tubing. the weight of the frame is just over 800 lbs.
IMG_20190219_105222582.jpg (145.13 KiB) Viewed 783 times
floor plan for Health dept..JPG
My design. It's not quite exact to the original. but it will look close enough.
floor plan for Health dept..JPG (139.92 KiB) Viewed 933 times
1961 shasta.jpg
The photo I used to design the trailer.
1961 shasta.jpg (28.46 KiB) Viewed 933 times
Last edited by R. W. Alexander on Mon May 13, 2019 4:47 pm, edited 1 time in total.
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Re: 1961 Shasta Areoflyte build for food trailer

Postby R. W. Alexander » Sun May 12, 2019 4:44 pm

The floor is 3/4 inch cdx plywood that has the Henry's asphalt to seal the wood from moisture. Before that I did two coats of red primer to all the frame members.
I wanted to put in Jalousie windows to give the trailer the look of the original. I found that the B.O.R.G. (big orange retail giant, the Home depot) carried them.
I first did a small one on the entry door to make sure they would work. Which they did. so I ordered two 18 by 24 windows for the front and three 24 by 24 inch
windows for the order window and by the sink area. Having these types of windows would allow maximum ventilation for the trailer.
Attachments
IMG_20190225_154709879.jpg
IMG_20190225_154709879.jpg (218.23 KiB) Viewed 931 times
IMG_20190220_143105964.jpg
IMG_20190220_143105964.jpg (138.28 KiB) Viewed 931 times
IMG_20190228_160342662.jpg
IMG_20190228_160342662.jpg (140.55 KiB) Viewed 931 times
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Re: 1961 Shasta Areoflyte build for food trailer

Postby R. W. Alexander » Sun May 12, 2019 4:49 pm

Some photos of the wall section.
Attachments
IMG_20190221_154752464.jpg
frame parts cut out on the CNC router
IMG_20190221_154752464.jpg (157.39 KiB) Viewed 930 times
IMG_20190301_152519649.jpg
alignment pins to hold the parts together
IMG_20190301_152519649.jpg (142.92 KiB) Viewed 930 times
IMG_20190304_161237247.jpg
Frame parts for the walls
IMG_20190304_161237247.jpg (146.65 KiB) Viewed 930 times
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Re: 1961 Shasta Areoflyte build for food trailer

Postby Atomic77 » Sun May 12, 2019 5:10 pm

Very nice work. Fast too!

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Re: 1961 Shasta Areoflyte build for food trailer

Postby aggie79 » Mon May 13, 2019 7:29 am

:applause: :thumbsup: :applause:
Tom (& Linda)
For more on our Silver Beatle teardrop:
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Re: 1961 Shasta Areoflyte build for food trailer

Postby Atomic77 » Mon May 13, 2019 10:57 am

Interior pictures?

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Re: 1961 Shasta Areoflyte build for food trailer

Postby R. W. Alexander » Mon May 13, 2019 3:19 pm

More build photos. Before the side walls went up I coated the walls with epoxy while they were on the saw horses.
It's a lot easier to epoxy while the 12 foot long wall sections are horizontal instead of vertical.
I also needed to fix a mistake. I originally had a 90 degree V bit cut into the 1/4 inch Baltic birch about 8 inches
apart. Each side is made up of 3 sections, that were glued together. Some of the birch plywood pieces had curved
up slightly, so when I ran the router. One v groove would be slightly deeper than the next plywood piece that would get
glued. So I made the decision to add some 3/4 inch by 1/4 inch thick batten strips to hide the v grooves.
Attachments
IMG_20190319_155410983.jpg
Dry fitting the Jalousie windows.
IMG_20190319_155410983.jpg (182.24 KiB) Viewed 805 times
IMG_20190318_162335135.jpg
rear frame view
IMG_20190318_162335135.jpg (203.23 KiB) Viewed 805 times
IMG_20190315_123243346.jpg
Framing up the top, with 1 1/2 inch by 2 inch deep frame members.
IMG_20190315_123243346.jpg (219.81 KiB) Viewed 805 times
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Re: 1961 Shasta Areoflyte build for food trailer

Postby R. W. Alexander » Mon May 13, 2019 3:30 pm

At this point I needed to move the trailer into the garage, because of rain and snow. In one of the photos you can see the
awing. There are 3 on the trailer. The largest goes over the order area on the trailer. There is one on the front. And a
smaller one to the back by the door. They can be fastened from the inside to provide protection to the windows and to
provide protection from the sun. i also used full length piano hinges.
Attachments
IMG_20190323_165559389.jpg
Test fitting the awnings.
IMG_20190323_165559389.jpg (133.04 KiB) Viewed 803 times
IMG_20190326_114102386.jpg
Putting on the door
IMG_20190326_114102386.jpg (120.21 KiB) Viewed 803 times
IMG_20190323_174502654.jpg
Only a 1inch to spare. I had to put on 12 inch tires temporarily to get it inside the garage.
IMG_20190323_174502654.jpg (122.24 KiB) Viewed 803 times
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Re: 1961 Shasta Areoflyte build for food trailer

Postby R. W. Alexander » Mon May 13, 2019 3:40 pm

The walls are a total thickness of 2 inch thick. 1/4 inch Baltic birch outside, 2 pieces of 3/4 inch ply glued
together for the frame and 1/4 inch interior utility grade ply for the interior walls I got some 1 1/2 inch foil
covered ridged insulation for the walls, and fiberglass insulation for the ceiling.
Attachments
IMG_20190402_131442581.jpg
Insulation.
IMG_20190402_131442581.jpg (161.15 KiB) Viewed 801 times
IMG_20190404_091402062.jpg
Rear view of the inside.
IMG_20190404_091402062.jpg (120.32 KiB) Viewed 801 times
IMG_20190401_145007387.jpg
Front view of the inside.
IMG_20190401_145007387.jpg (115.37 KiB) Viewed 801 times
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Re: 1961 Shasta Areoflyte build for food trailer

Postby R. W. Alexander » Mon May 13, 2019 3:44 pm

Some photos of the interior counter top being built.
Attachments
IMG_20190405_160527243.jpg
The serving area.
IMG_20190405_160527243.jpg (139.14 KiB) Viewed 800 times
IMG_20190404_151930844.jpg
The counter top goes completely around the inside of the trailer.
IMG_20190404_151930844.jpg (115.89 KiB) Viewed 800 times
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Re: 1961 Shasta Areoflyte build for food trailer

Postby R. W. Alexander » Mon May 13, 2019 3:54 pm

I hate painting. But family could not come over in the morning when it was cooler to put on the primer and paint.
I used some Total boat grey primer to do the exterior. It was good and bad. Good because you can see where you
missed with the paint. But bad because it heated up fast when the sun hit it. I used some thinner to slow down the
dry time... but it helped only a little bit. If you look at the photo you can see waves in the plywood. It will get covered
with some painted aluminum. but on the back where the bending plywood is forced into a curve. There is no waves
in the plywood.
Attachments
IMG_20190425_131514716.jpg
Primer 2 coats total.
IMG_20190425_131514716.jpg (233.34 KiB) Viewed 806 times
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Re: 1961 Shasta Areoflyte build for food trailer

Postby R. W. Alexander » Mon May 13, 2019 4:28 pm

I had some fun with this. I took some plywood, and cut the wing shape. I then coated it in epoxy. I then took some
left over aluminum flashing materiel and made some bends in a small hand brake and pop riveted the material to
the plywood. I then added them to the sides of the trailer with some 1/2 inch stand offs.

the interesting thing about the Shasta wings. Originally when they came out people took them off their trailers. Now
if you can find them. People want them back on.

My daughter does not like them but my son-in-law does
Attachments
IMG_20190411_083458706.jpg
IMG_20190411_083458706.jpg (148.01 KiB) Viewed 796 times
IMG_20190409_171659440.jpg
wings
IMG_20190409_171659440.jpg (157.27 KiB) Viewed 796 times
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Re: 1961 Shasta Areoflyte build for food trailer

Postby R. W. Alexander » Mon May 13, 2019 4:35 pm

Where I'm at this point. I'm currently waiting for the electric 2.5 gallon water heater and pump. The exterior painting
was finished two weeks ago. Two coats of white boat paint on the upper section, with a nice light blue on the bottom.
I added some tear drop clearance LED lights on he sides, last week.
Attachments
IMG_20190503_152706_01.jpg
IMG_20190503_152706_01.jpg (146.44 KiB) Viewed 794 times
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Re: 1961 Shasta Areoflyte build for food trailer

Postby redbicycle » Tue May 14, 2019 9:17 am

It looks like a great place to be making crepes.


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Re: 1961 Shasta Areoflyte build for food trailer

Postby MJWBuffalo » Wed Oct 23, 2019 11:04 am

Any updates?

I am curious how it performed?
Heat build up inside?
Any other insights?

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