1978 Boler Complete Restoration / Rebuild - Page 8 - Fiberglass RV


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Old 05-28-2013, 11:34 PM   #99
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Working on the Inside

After getting the underside patched up and coated with Herculiner, it was time to get all of those holes and frame-rail cut-outs fixed up from the inside. On average the holes were one inch in diameter, so I packed them with resin saturated FG mat and the top piece of mat was bigger to nicely close everything off.

Here is a pic of a couple of the finished holes:

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And here are examples of the reinforced frame-rail openings:

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Some of the original fiberglass around the above rail forms was paper thin so I went ahead and added a couple layers of mat and all is good and solid. Really makes me wonder how these Boler bodies were made with such a huge variation in thickness of the FG.
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Old 05-28-2013, 11:49 PM   #100
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Wheel Well Cutting Fun!

So, this was quite a workout...both physically and mentally! Remember I mentioned in a past post that the wheel wells on our Boler were whacky. And since there were gouged out tire troughs in the fiberglass underneath from the old tires that I had already fixed, I didn't want to have this happen again. It would be triple the work to do it later.

Here is a reminder of our wheel wells:

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Using a multi-speed oscillating power tool, the slope was cut out...this was a good workout! Tight access in places, curves, and variable thickness of the FG (1/2 inch thick in places!)...broken cutter, smoke, a few fancy words thrown in for good measure. But I pressed on:

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Time for a glass of wine...or two!
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Old 05-29-2013, 12:06 AM   #101
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Wheel Well Fiberglass Fix

Now that I had a couple days of recovery and stopped questioning myself as to why I'm doing this (I am enjoying it...and envisioning us camping already!), it was time to get the fiberglass work cookin'. I got 6 packages of FG mat, many brushes, Nitrile gloves, hardener and a huge jug of resin from Home Depot.

I had to make "rough" forms so I had something to lay the new fiberglass on. I had some unused board left from framing photos, so put that to good use. It was covered with wax paper so the glass wouldn't stick to it.

Here is one of the forms:

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Got suited up, respirator on, eye protection, double Nitrile gloves. I ended up doing 4 or 5 or maybe 6 layers of fiberglass mat, but in two sessions. The reaction of resin hardening is exothermic (emitting heat as it dries) so it started drying much faster than I anticipated after several layers were built up. Sections got quite warm.

After waiting for things to cure, I scruffed it up with 80 grit, cleaned with acetone, and finished the job. After two days of work, things look great, nice and solid, and I should not have any issues with my tires hitting anything. I'll just need to still apply the Herculiner underneath though.

Here you have the pics:

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Old 05-29-2013, 07:50 AM   #102
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nice work...
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Old 05-29-2013, 08:21 AM   #103
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Just curious why you didn't tilt the well outboard, looks like you could gain a couple inches. Odd that they were tilted like that. Very nice glass work!
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Old 05-29-2013, 11:09 AM   #104
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Just curious why you didn't tilt the well outboard, looks like you could gain a couple inches. Odd that they were tilted like that. Very nice glass work!
Kevin, thanks! Well, from my calculations the modifications should be more than sufficient - but I'm not 100% sure on your question - at least much better than they were before. We now have plenty of space for the wheels to play in. Indeed, this was a strange design flaw...
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Old 05-29-2013, 11:18 AM   #105
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What I meant was that it appears that the hump is tilted inboard, giving you clearance where you don't need it. If you could tip the top of the hump more outboard, might give you a couple inches in the aisle. Although looking at the pics now it looks like the inboard face is pretty vertical, hard to tell. Seems like you'd mold the well to provide equal clearance all around, plus vertical travel. Weird use of volume. Unless that rear clearance is necessary to remove the wheel from the well.
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Old 05-29-2013, 11:48 AM   #106
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I agree with Kevin. Seems like you could slice straight down in the inside curve and make it flat and you would pick up a tad more interior space. BUT its done now and the wheel well will be covered. Looks like a mushroom on its side. Still NICE
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Old 05-29-2013, 01:14 PM   #107
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What I meant was that it appears that the hump is tilted inboard, giving you clearance where you don't need it. If you could tip the top of the hump more outboard, might give you a couple inches in the aisle. Although looking at the pics now it looks like the inboard face is pretty vertical, hard to tell. Seems like you'd mold the well to provide equal clearance all around, plus vertical travel. Weird use of volume. Unless that rear clearance is necessary to remove the wheel from the well.
Ok, I now see what you're getting at. I agree, the pics make it seem like there is an outward tilt but that's an illusion. They are totally vertical on the inside. I'm going to leave them alone at this point and move on.

Mike...ha, they do look like mushrooms! Uniquely mine!
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Old 05-29-2013, 09:23 PM   #108
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Uniquely mine!
And that works!
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Old 06-01-2013, 02:02 PM   #109
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Fiberglass Floor Treatment

After completing all the fiberglass work involving the floor and wheel wells, I gave it a good wipe-down with acetone to get rid of any loose FG powder and fibers. Before all the work started, it was washed down and scrubbed with detergent, but the stains of age and a faint odor (aged fiberglass?) remained.

Here are a couple before pics:

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Even though we will be putting down 3/4" plywood subfloor and this will be all covered up, I wanted it to look fresh and sealed well. And after seeing Robert Johans doing a similar treatment in his last Boler reno, we went ahead and coated it with a garage floor epoxy paint. I first tested it on a scrap FG piece and it looked great. Seemed to really bond with the FG and wouldn't lift up.

Here is what we used:

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Eventually the rest of the inside will be coated with the epoxy paint before we glue in the Reflectix insulation. But more work is to be done on the rest of the inside. Here are a couple pics of the finished floor:

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Old 06-01-2013, 02:18 PM   #110
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I was going to do the same thing Slav - again as you after seeing Roberts. His was greyer (if that is a word). I like the looks of yours.

Good job.
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Old 06-01-2013, 03:04 PM   #111
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I was going to do the same thing Slav - again as you after seeing Roberts. His was greyer (if that is a word). I like the looks of yours.

Good job.
Thanks Mike! I wonder if the color variation is due to lighting. Anyways, I'm quite pleased with the outcome.

Slav
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Old 06-01-2013, 03:08 PM   #112
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I wonder if all of our garage floors look as nice as our trailers do while under renovation. That stuff looks really nice and durable.
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