1982 Boler remodel, rebuild, restore - Page 2 - Fiberglass RV


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Old 08-01-2014, 11:22 PM   #15
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Name: Martin
Trailer: Boler
Ontario
Posts: 179
When we started this project we decided that we would mostly be treating it as bedroom on wheels. A comfortable place to sleep, carry our food and supplies and a warm dry place to retreat to in foul weather. So a good bed was tops on our list of wants. My wife knows a guy who makes mattresses in a small factory in Toronto. She dropped in for a visit, brought the Boler cushions, laid them out on his table and asked if he could make a mattress to match the contours of the trailer with some extra width and thickness. He said no problem. Here's the result. Probably too thick but it sure is comfortable. It's all foam, no springs.
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Old 08-01-2014, 11:51 PM   #16
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Name: Martin
Trailer: Boler
Ontario
Posts: 179
1982 Boler remodel, rebuild, restore

In some of my earlier pics you could see the Progressive Dynamics convertor mounted under the bed. As work progressed I was running the assorted wires I thought I would need and left them bundled up at the convertor. I've now cut them in to the convertor, both 12 volt and 120 volt. Took me quite some time as the PD instructions are horrendous. I did a lot of online searches, both on this site and others, bugged a friend at work who has an electrical background and went slow. Fortunately I've done some basic household wiring and I rewired my 1950 Plymouth with an aftermarket kit so I felt confident enough to proceed. Heres a few shots of the proceedings.

Convertor mounted with the 12 DC wires attached to a terminal block. I'll use no more than six of these circuits.

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Convertor with breakers(Home Depot) installed and 120V wiring cut in

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Backside of the convertor with the 12V stuff attached to the terminal block. Thicker white wires are the 120V stuff. White/green/black 8 gauge wire at the bottom right is shower power coming in. White wires at the top right attached to the bus bar are all of the assorted grounds. This bus bar is also grounded to the trailer frame and connected directly to the battery(whenever I get one)

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Shore power connection going into back of trailer. It's a Furrion 30A plug which is a boat part. I got the convertor, shower power plug and lots of other stuff at Vintage Trailer Supply in Vermont. I also put in LED tail lights. Got those on sale at Princess Auto.

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Most of the wires are still not attached to anything at the other end but I did plug the trailer in and started turning on breakers and inserting fuses. I used a test light and meter to check for power at the ends of the wires and all seems in order. Nothing tripped, no smoke, no flames, surprisingly ....

If anyone is considering a convertor upgrade/change the Progressive Dynamics is great IMO. If you have a bit of wiring knowledge and get past the lousy instructions the installation is not as bad as I imagined.


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Old 08-06-2014, 05:56 AM   #17
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Name: Martin
Trailer: Boler
Ontario
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So I spent the last few days getting the beginnings of the kitchen area installed. Having made the bed a bit bigger we lost some counter space. I tried to make that up by shortening the gaucho bench and extending the counter towards the front of the trailer. I think it worked out ok. For a counter I bought an in stock piece from HD which modified to fit, a new 2 burner Suburban stove top, a cheap bar sink from Amazon and a laundry tap again from HD.
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The wires a for the water pump switch, a 12 volt outlet and a120v plug with two built in USB jacks.
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The new front bench which I built quite a while ago. Storage on the left and a porta potti on the right. Got the idea for the porta potti setup from another build on this site. Thanks for that.
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Bones of the kitchen are in. I still have to make all the connections, install the fridge which I'm waiting on and build the face frame of the cabinets(need fridge first).
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Overall it's coming along pretty well. But I've got four weeks until we're going on a two week road trip.


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Old 08-06-2014, 06:23 AM   #18
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Name: Morgyn
Trailer: Boler
Nova Scotia
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I keep sighing with jealousy over the work you've done so far! Bought an 81 Boler last week so I've been following your progress and making notes!




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1981 13' Boler
Nova Scotia
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Old 08-06-2014, 04:11 PM   #19
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Name: andrew
Trailer: 17 boler
Ontario
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Hi Martin

Your friend in Toronto, would he be interested in making another mattress?
Do you live in Toronto? I live just east in Peterborough

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Old 08-06-2014, 04:12 PM   #20
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Name: Martin
Trailer: Boler
Ontario
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Thanks for the kind words. I'm no expert thats for sure. I just go slow and borrow liberally from the folks here. There's plenty of expertise on this site.


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Old 08-06-2014, 06:10 PM   #21
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Name: Martin
Trailer: Boler
Ontario
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1982 Boler remodel, rebuild, restore

Greetings Andrew. I'm sure he would make another mattress. You would just have to bring him a template of what you want. I made the mistake of ordering it too thick and I was too precise with the measurements. As a result it's a very tight squeeze. It's still workable and quite comfortable. If you're interested message me and I'll get you his address. He's around 400 and Finch. I just south of you at the bottom of the 115.


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Old 08-06-2014, 11:03 PM   #22
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Name: Nate
Trailer: 1981 Casita 13. TV: 2011 Honda CR-V
Wisconsin
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Now that the bed is basically good to go here's a couple of shots of my slightly narrower closet. It'll have an upper and lower section. Fixed shelves at different spacing up top for a cutlery tray, etc. The top shelf will have a 120v plug to charge phones etc and keep the wires out of sight. I'll also drill a hole the run the wires to a small flat screen mounted on the bed side of the closet.
Comments, questions, suggestions always welcome. Thanks to all, I've borrowed liberally from numerous threads I've been reading here.
How is the closet attached to the shell? Did you just glue the ends of the plywood to the fiberglass, or attach some sort of flange?

We'll also be increasing our bed size on our 1981 Casita, which requires me to shrink the closet. Wondering if it would take less time to create one from wood like you did instead of cutting a few inches out of the middle of the fiberglass one, and then bonding it back together? Any thoughts?
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Old 08-07-2014, 12:42 AM   #23
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Trailer: Casita SD17 2006
California
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Martin, your wiring is very sanitary, like it.
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Old 08-07-2014, 06:18 AM   #24
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Name: Martin
Trailer: Boler
Ontario
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Nate, the side of the closet closest to the bed and the top front part of the face frame is attached to blocks of wood that I bonded to the fibreglass shell using the strongest construction adhesive I could find. I cut out the ensolite to match the size so the wooden block, used a generous amount of adhesive, let it set up over night and drove some screws through the side wall of the closet into the block. On the door side, the closet lines up right at the edge of the door opening. I peeled away some old door weatherstripping, carefully drilled some pilot holes through the fibreglass shell and into the plywood of the closet. Seems pretty solid. This is the first RV I've tinkered with so we'll have to see how it holds up after a few thousand kilometres of towing. As for cutting up the original closet and reusing it, you'll also have to modify the door, shelves etc. I'm redoing the entire interior so for me it was an easy decision to just build it all from scratch.


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Old 08-07-2014, 06:26 AM   #25
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Name: Martin
Trailer: Boler
Ontario
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Dave thanks for the compliment. I like all things mechanical, especially custom cars and hot rods. So I admire the effort and attention to detail that goes into those kinds of projects. Perfect brake and fuel lines, neat wiring are details that might get overlooked but I enjoy looking at them. My work is a far cry from those that I get inspiration from but with every project I hope to get a little better.


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Old 08-07-2014, 07:05 AM   #26
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Name: Roy
Trailer: 1972 boler American and 1979 Trillium 4500
Ontario
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Looking good Martin!

You've come a long way since I saw it. I like the way you have configured the front and tied into the metal bar at the door.

You may have changed my mind on the PD4045, I never thought of installing it upside down. I saw my first one in the new Sidekick installed under the front streetside bench tucked in behind a monitor of some kind. It was a real PITA to get at - you had to get around the door of the unit. Upside down it would easier access to the fuses with the table up or down. The actual location can be seen in page 1 their brochure, http://www.greatwestvans.com/wp-cont...el-Trailer.pdf

Ask your friend if you can post his business details for the matress. It would be nice if we could all access him easily.
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Old 08-07-2014, 11:08 AM   #27
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Name: Martin
Trailer: Boler
Ontario
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Greetings Roy. My initial plan was to put all mechanicals on the sink side but then thought it may be wiser to separate water and electrical. Hence the moving of the convertor next to the closet. I now have anything that may leak well away from whatever may spark. Not sure if it's really necessary but it's done, it works and that's good enough for me. When I rebuilt the front bench I had in mind our conversation about the weakness of the door frame. So I tried to get the bench up tight to the metal brace and drove a few screws through the fibreglass and into the bench. It's very solid now on both the handle and hinge side and the door closes with a nice solid thud. The door is still not straight in the frame. I measured the opening and it's not perfectly square. I measured the door and it's not even the same width from the top to the bottom. The frame may have moved over the years but the door didn't change size over the years. Even if the opening was perfect it still won't look right. When I get to working on the outside of the trailer I'll scribe and sand the door edge to make the gap less noticeable.


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Old 08-07-2014, 12:52 PM   #28
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When I get to working on the outside of the trailer I'll scribe and sand the door edge to make the gap less noticeable.
Flapper pad on the angle grinder does that nicely.
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