1975 Boler Complete Restoration....my once in a lifetime project! - Page 5 - Fiberglass RV


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Old 11-22-2018, 09:01 AM   #57
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Name: Shannon
Trailer: 1975 13' Boler
British Columbia
Posts: 85
The front and back window required more work to create a 1" thick layer with precise curves at the corners, straight lines between the corners and a smooth edge since this would be visible. I left enough space for the gasket to be installed later for the plexiglass windows. Worked carefully, lots of sanding, 2 coats of primer and I was pretty happy with results! I received a lot of assistance from my helper in the background
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Front window 1.jpg   Front window finished.jpg  

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Old 11-22-2018, 09:12 AM   #58
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Name: Shannon
Trailer: 1975 13' Boler
British Columbia
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Back to my unhappy discovery...After rinsing the inside of the trailer with a hose, I discovered water that kept surfacing in a knot hole in the plywood at the back of the trailer. I thought it would dry out with time in the warm weather but that didn't happen. After removing a small piece of the floor, I discovered that the plywood in this area had began to rot and there was a lot of water underneath! Obviously a water problem from before my washing! I couldn't leave this since it would be very, very difficult to fix down the road. I drilled small holes in the rest of the plywood floor to find any other wet areas and removed this plywood. Wasn't the most fun job but not the worst either! Help from a friend made it a lot easier!!
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Wet floor 1.jpg   Wet floor 2.jpg  

Plywood removed 1.jpg   Plywood removed 2.jpg  

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Old 11-22-2018, 09:21 AM   #59
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Name: Shannon
Trailer: 1975 13' Boler
British Columbia
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Cut new pieces of 1/2" plywood and adhered them to the floor with lots of PL Premium adhesive. I used screws through the bottom of the trailer to pull the plywood close to the floor. After removing the screws once the adhesive was cured, I meticulously filled each hole with black Sikaflex 252 (sigh...why does everything have to be so hard?! ). Invisible repair in the end!! I applied a bead of Sikaflex to all the seams where the plywood floor met the trailer so water couldn't get below the floors in the future should there be any water issue (shouldn't be but plan for the worst ).
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Old 11-22-2018, 09:33 AM   #60
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Name: Shannon
Trailer: 1975 13' Boler
British Columbia
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Before laying the rest of the strips in the trailer, I wanted to place conduit to run my electrical wiring. I purchased 1/2" inside diameter, flexible plastic conduit and 3/8" inside diameter plastic waterline and adhered them to the fibreglass with hot melt glue. Worked really well! Once the foam insulation was sprayed in, this conduit wouldn't go anywhere!
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Wiring conduit 1.jpg   Wiring conduit 2.jpg  

Wiring conduit 3.jpg  
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Old 11-22-2018, 09:38 AM   #61
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Name: Shannon
Trailer: 1975 13' Boler
British Columbia
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I created "junction boxes" to be taped over before insulation was sprayed in...
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Junction box 1.jpg   Junction box 2.jpg  

Junction box 3.jpg   Junction box 4.jpg  

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Old 11-23-2018, 12:11 AM   #62
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Impressive. Looking forward to more updates and photos.
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Old 11-23-2018, 08:06 AM   #63
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Name: Shannon
Trailer: 1975 13' Boler
British Columbia
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Now to attach strips to the rest of the trailer. I used 1 1/2" wide strips where I knew there would be seams in the panelling and 1" wide strips everywhere else. I planned seams to be hidden inside cabinets where I could and to split the tight radius in the 4 corners of the trailer (the plywood is bendable but not enough to fit that radius without breaking!). The spacing of the strips was determined by the amount of curve in the trailer...the tighter the curves, the closer the strips. The final result was essentially a contour map of the inside of the Boler!
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First layer 1.jpg   First layer 2.jpg  

First layer 3.jpg  
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Old 11-23-2018, 08:12 AM   #64
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Name: Shannon
Trailer: 1975 13' Boler
British Columbia
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I purchased a 10 gallon fresh water tank so I could plan for the location of the backing to attach the water fill. Final location of the tank will be centered at the rear of the trailer.
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Water tank 1.jpg   Water tank 2.jpg  

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Old 11-23-2018, 08:30 AM   #65
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Name: Shannon
Trailer: 1975 13' Boler
British Columbia
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Now onto the very repetitious process of adding the next 3 layers of 1/4" bending plywood strips. Roll Titebond III onto each surface, pin nail the strip and repeat and repeat.... At least I could work with longer strips but there was still a lot of cutting and fitting where the trailer was curved and around the electrical conduits. "I'm only doing this once, I'm only doing this once..."
As a note, this work is taking place in September and October of this year. I was very determined to finish the strips so that the trailer could be insulated for the winter allowing me to get on with finishing the interior. The minimum temperature required for Sikaflex to cure is 10 degrees Celsius and storing the trailer inside a structure was not an option. It was an unbelievably warm fall and I was very fortunate to get the temperatures I needed!!
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Finished strips 1.jpg   Finished strips 2.jpg  

Finished strips 3.jpg   Finished strips 4.jpg  

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Old 11-23-2018, 08:56 AM   #66
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Name: Shannon
Trailer: 1975 13' Boler
British Columbia
Posts: 85
Every opening and component had to be thought out in advance to insure there was proper backing and strips for attachment. Since the rear of the trailer will be a permanent bed (the trailer is intended for 2 - 3 people and I didn't want a table that had to be made into a bed each night...I'll post interior plans in the future) I decided to add an access door on each side at the rear of the trailer. Now I'll have access to storage that would have otherwise been very difficult to reach. It's all about maximizing space in these little trailers! The access doors are manufactured by Vision Manufacturing in Summerland, B.C. Here are some pics...
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Storage door 1.jpg   Storage door 2.jpg  

City water and 120V inlet backing.jpg   Water fill backing.jpg  

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Old 11-24-2018, 11:02 AM   #67
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Name: Shannon
Trailer: 1975 13' Boler
British Columbia
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The last construction step before insulation was to cover the tail lights with 1/8" bending plywood. This would have been a challenging area for the insulator to spray foam without a lot of clean up after. Covering it would provide backing and much less work. I made a template from cardboard, fine-tuned the piece of 1/8" bending plywood and glued it in place nailing through small blocks that I removed after the glue dried.
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1:8%22 bending plywood for tail light.jpg   Tail light.jpg  

Covered tail light 1.jpg   Covered tail lights.jpg  

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Old 11-24-2018, 11:09 AM   #68
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Name: Shannon
Trailer: 1975 13' Boler
British Columbia
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The last step before insulation (yay!!!!!!) was to cover all the strips with duct tape to protect from foam over-spray. No point in using just silver duct tape....
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Duct tape 1.jpg   Duct tape 2.jpg  

Duct tape 3.jpg   Duct tape 4.jpg  

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Old 11-24-2018, 11:13 AM   #69
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Name: Shannon
Trailer: 1975 13' Boler
British Columbia
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Hooked up and ready to tow to the spray foam insulation shop!!
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Inaugural tow.jpg  
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Old 11-24-2018, 11:23 AM   #70
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Name: Shannon
Trailer: 1975 13' Boler
British Columbia
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Back from the insulation shop! They did a great job! A little shaving of high spots will be required (which I expected) and will do before the panelling goes on but I would rather that than a thinner layer of insulation. Should make for a pretty cozy Boler!
Attached Thumbnails
Insulated Boler 1.jpg   Insulated Boler 2.jpg  

Insulated Boler 3.jpg   Insulated Boler 4.jpg  

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