1978 Boler Complete Restoration / Rebuild - Page 15 - Fiberglass RV


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Old 06-09-2014, 11:35 AM   #197
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I screwed hardboard on the outside matching the profile to give it shape. Then added either bondo or gelcoat (bondo is not the best for this as in bigger patches it can crack after a while). Then I added a layer of fiberglass on the inside. Let it dry, then another and so on. I didn't use a form on the inside, as the fiberglass took the shape of the outer mold.
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Old 06-09-2014, 11:46 AM   #198
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Quote:
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I screwed hardboard on the outside matching the profile to give it shape. Then added either bondo or gelcoat (bondo is not the best for this as in bigger patches it can crack after a while). Then I added a layer of fiberglass on the inside. Let it dry, then another and so on. I didn't use a form on the inside, as the fiberglass took the shape of the outer mold.
Sounds good, thanks.
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Old 06-10-2014, 10:32 AM   #199
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A little rain and wind yesterday wasn't enough to give me confidence, so I pulled out the hose. The product fixed it. It was a leak that only appeared with heavy storms.
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Old 06-10-2014, 01:03 PM   #200
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A little rain and wind yesterday wasn't enough to give me confidence, so I pulled out the hose. The product fixed it. It was a leak that only appeared with heavy storms.
I think I missed you mentioning where this leak was. Was it around the front window?
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Old 06-10-2014, 02:42 PM   #201
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The front window and seal where new last year, but when the shop went to install they "upgraded" to marguard, a much more flexible and scratch resistant material, the only problem is on the freeway the wind blew it out of the seal (downside to flexible). I managed to get it back in, and now travel with a rock guard on the window. I have since noticed that during storms the front window leaks. With everything appearing to be good I have had trouble finding the issue and changing the front window seems like an expensive solution as it is still new.
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Old 06-12-2014, 11:30 PM   #202
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1st Window

Started fitting the 1st window that needed FG work. As messy as it looked before, it looks quite decent now. And after some sanding and body filler I think it will be quite nice.

Here you have the modified cut-out followed by window sitting in it:

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Will get to work on the opposite window and kitchen window next....
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Old 06-24-2014, 06:14 PM   #203
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Side Windows

After a bit of a mess with the first side window, I decided to use scrap FG for most of the work on the opposite side window and the kitchen window. Still did the smaller corners with fresh FG, but in hindsight should have just used scrap pieces for those too. Anyways, here are some pics of the kitchen window.

First, securely screwed in the scrap piece followed by basting with FG on the inside:

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Next, traced out the size and cut out the new opening. Turned out pretty good and fits well after some fine-tuning:

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With the bigger side window I first secured the long scrap piece before basting from the inside. The corners were done from scratch:

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Once everything was well cured, I again traced out the outline of the window and made the cuts. Fits pretty good.

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There is more fine tuning to be done and of course the external body filler will be needed once I'm ready for that step.

I think I'll tackle that busted upper rear corner of our Boler, at least from the inside for starters.
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Old 06-24-2014, 06:21 PM   #204
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Nice! ill forward pics of my windows over the long weekend!
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Old 06-24-2014, 06:22 PM   #205
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You need to ditch and put 2 layers of fiberglass on the outside too, or it will show and possibly crack....fiberglass Dave
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Old 06-24-2014, 06:44 PM   #206
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Nice work Slav. Listen to Dave the FB man. Looking GREAT
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Old 06-24-2014, 08:27 PM   #207
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Good job Slav. Just a note for anyone needing scrap FG pieces. I picked up 12 window cut outs from a shell maker for free. Done many mods with them on the dune buggy.
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Old 06-24-2014, 10:43 PM   #208
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Thanks everyone for the good words! I guess it will be more work, but will take Dave's advice. Don't want all this and upcoming hard work to bite me.

Slav
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Old 08-21-2014, 10:47 AM   #209
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Belly Band is Off

Finally got a day I could put some more hard work into the Boler. First, wanted to get that belly band taken off and see how things looked underneath. It will need to be restored and shined up for sure. I plan to use stainless screws (anyone know if stainless and aluminum will react unfavorably?) instead of rivets. Not sure yet if only drilled into the top or all the way thru. Guess it would be cleaner to not drill thru the bottom of the band.

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As expected, under the band could almost make a guy cry. Filthy and kind of rotten in places. This one is on the driver side of the rig:

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And this one to the right of the door. You can really see how gross and frayed things look:

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What I'd like to do with this is clean it up as good as possible (any suggestions? acetone? water? soap?) and put a bead of something into the gap just to seal it up from future gunk buildup. I was thinking of some liquid rubber, if there is such a thing. Or there is that tar in a tube for roofing. Or would silicone be good enough? Doesn't need to be pretty, just functional.

Thanks for any tips!

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Old 08-21-2014, 12:27 PM   #210
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My trailer is very similar to a Boler. I was curious as to how the frame project came out. Did you remove the rust and repaint? I found a crack in my frame (1973 trailer), so I'm juggling different ideas: fix/strengthen or have a whole new frame made. Not sure yet. It looked pretty easy to separate the body from the frame on yours. I don't think mine would be quite as easy. What is the floor? Fiberglass? Mine is a thick, plywood floor, attached to the body via bolts, rivets, and fiberglass overlay. Interesting design. =P Thanks!

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Portland, OR
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