Does anyone have any advice on getting the ensolite off? I have a majority of it off, but it's not that easy..... I'm trying to get it ready to get it linex'd - -

curious if anyone has any certain "tricks"

Well, it's been a while since I've had any progress, but I'm back. My 5 year old son was diagnosed with diabetes in
May, and the camper project has been on hold for a while. Anyway, I just got my Boler back from the Rhino Liner guy,
and I'm pretty satisfied with the results. There are a few "globs" here and there, but I'm going to try to deal with them.
Fortunately, there was about 3/4 of a quart of material left over after he was finished spraying and I'll see what i can do
to fix some of the imperfections. The next stop...(once I've saved up a few $$) is the body shop for a new coat of paint.
Or, who knows....maybe I'll try to paint it myself. We'll see.

I'm also replace the back piece of plywood flooring. I was wondering what you used for a template for the new piece (did you use the one you cut out?) and how you cut the plywood out (how close to outside wall). Thanks for any information.

The old floor came out like mashed potatoes, so I had to use a large piece of cardboard cut loosely to fit as a template.
I used a compass to "scribe" a line onto the cardboard about two inches in. Then, without changing the compass, that line was transcribed onto the 3/4 ply. Fit like a glove. I cut the plywood square, so there was a gap due to the curvature of the walls. That gap was filled with polyester resin mixed with micro beads. It kinda made a paste like consistency. Once it set up, it got another "coat" that was rounded nicely with my trusty old finger. That made a nice smooth transition between floor and wall......(Fiberglass mat doesn't like to make 90 degree bends)First strip of glass was about 2" wide, 2nd piece was about 4", and so on until I had about 4 layers or so.

I have thought about doing the Rhino liner in my Scamp. How much did it cost? How much weight did it add? What about the smell? (I know you may not have answer for last question since your's is still open to air)




Donna

Donna,
The job cost me $1,800......a bit pricey to be sure, but I like the results. As far as the weight, I'm not too sure. But,
if I had to guess, maybe it added 60 or 70 pounds.
The smell was a bit overwhelming at first, but is is diminishing day by day. I had a test piece sprayed a few months back, and it is now completely odorless. The camper won't be completed until at the very least next spring so, I have time for the odor to dissapate.
According to a Rhino rep that I called, when it is completely cured it is non toxic.......(who knows for sure?)

The one thing I know for sure is that is doesn't have much in the way of insulating qualities......I hope sweating won't be a problem.
I don't do too much winter camping, so I hope this doesn't become an issue. Windows will be open most of the time.

Time will tell if this was a wise idea but, as I said, I like the way it looks....neat, seamless, and wipeable.

Thank You for the info Brian,
Donna

You know, it just occurred to me that Rhino lining may just be the hot ticket for a floor covering. In the event that someone is doing a complete resto, then they could Rhino the floor before finishing the interior and it would be sealed. Since floors tend to rot because of water pooling on top, it could be sealed on that side, and the underside could be left open to allow the wood to breathe naturally.

Just got my baby back from the painter! Now I can start putting her back together!!

Nice matching with your towing vehicle. BTW what is the towing capacity of the Scion?

Can't wait to see more pics.

Sleek!

The taillight cups look great. I read back in this thread, so I understand that you glassed them in without the usual riveted rims - can you tell how you went about that?

Did you glass them in from inside and then grind the rims off? Take them off and then..

Also, just curious: Is the belly band going back on? Or are you going "sleek" in that area too?

Thanks,

Raya

I cut the flanges off the light cups and clamped them in place. I learned fiberglassing as I went and this was one of the most pain in the butt things I did.....but I wanted the look....and I'm pleased. The belly band is gonna go back on. I like the fact that it sticks out at the widest point of the body and acts like a buffer so the body won't get scratched......

Thanks, Scott!

I like the belly band on the Boler/clones too. I like the "ring of Saturn" thing it has going (although it does tend to collect dirt and whatnot on the top flange). They look great polished up, I think

Your taillights look great! I had thought if I ever painted that I would drill out the rivets, fill the holes, and glass the lights in, but I hadn't thought about eliminating the flange for a smoother look, so that intrigued me.

Raya

The Scion(according to the manual) has NO towing capacity...... However, the engine is larger than the old style "boxy" model and in my opinion is plenty powerful. If I hit any serious hills or mountains, I'll be taking it easy for sure.......

It's not just a matter of engine size, but wheel base, too. A trailer is much more likely to do the steering for you when you have a short wheel base or not enough weight over the front wheels to counteract the lever-action of the trailer as it tilts forward and downward on the hitch when you brake or the trailer bounces.

When we repainted our Boler, I had the belly band off as well. The flange measured any where's from 5/8" to 1 1/2" so I marked it with a spacer and a pencil and ground it back to a common width. When I reinstalled the band I had to cut it shorter by about 1 1/2" because of the smaller sizing. I then polished the metal band with aluminum mag and wheel cleaner. Sure made a difference...... at least in my minds eye.
Thanks for the pictures. Looks like a very nice job. You're going to get a lot of looks when you go camping.
Jim

I love the XB & Boler look....

wish my 72 looked that good!!

Sorry - forgot most recent photos of mine

Click to view attachment

Click to view attachment


Still need some shots of completed outside - - and inside with my curtains and new front cushions....

Cut the holes in the benches for access. I ordered 4 interior window trim rings which had the correct profile
to rest panels in. The cover panels are 1/2 inch StarBoard. Oh, and, the LEDs went on today!

Brian, One sugestion:
Take a die grinder and cut the body back a little more from around the frame openings front and back. There is some different colored edge welting that you cane put on after to finish them off.
The reason being, over the years most or the frame cracks and breaks I have seen tend occur just behind the body opening. What happens is mud and water build up in there and doesn't get enough expose to air circulation. It is a spot most people don't think to hose out good after they have been on a muddy road.
You are doing a first class job on your rebuild.