1979 Trillium Restoration by The Egg Plant

[Robert Johans]

A couple years ago, we made some repairs to a leaky front window on this Trillium. Now it's back because the rear windows are shot too...

The Trillium window is mounted through its aluminum frame with screws that twist into inner frames made of plywood. Over time, the window pulls away from the FG shell body allowing water to seep in, which in turn saturates the plywood.

This wet wood rots over time and causes the screws to rust, which further weakens the window seal.

The only appropriate repair is to remove the old, rotten wood and glass in replacements. But instead of plywood, we will use a product called NyloBoard — a resin/wood composite material that is impervious to rot. And unlike something akin to "Trex", NyloBoard has terrific strength holding screws.

[Reid Larsen]

Having a Trillium w/ leaking windows and potential wood rot issues is NyloBoard locally available? I'm just over the hill from you i n the valley. Sounds like a great product for this application.

[Robert Johans]

Contact the manufacturer for availability in your area.

[David Tilston]

How does the weight compare to plywood?

Any secrets you want to share on separating the Ensolite from the plywood?

[Robert Johans]

The NyloBoard is denser and heavier than plywood, but the frames are only 3" wide with a 45° bevel along the long sides.

Separating the Ensolite from the original plywood was not easy. I used a sharp putty knife, razor blade and patience.

[David Tilston]

Yea, not easy. I have done one back window on a Trillium 4500. Only 23 windows to go.

I like grinding fibreglass much better.

[tbclinton]

Hi Robert,
We just purchased a 79 Trillium Jubilee and I am just starting to look at products to replace the original ensolite. Can you tell me what you are using? Thanks.

[Robert Johans]

We are not replacing the Ensolite on this project. The current condition is decent.

Several threads elsewhere on this Forum already available to you about ins and outs of replacement Ensolite.

[Robert Johans]

It has been a while since my last post about this project. Been awfully busy...

The owner of this Trillium decided that with all of the windows out and the internal frames being rebuilt, now would be the opportune time to have the trailer repainted.

We thought the body was in relatively decent shape, but the current paint job was horrible. So we stripped everything off the exterior. That, and a little scraping revealed some other problems with the gelcoat and fiberglass. Especially around the window corners and door frame.

[Robert Johans]

As is usually the case, one thing lead to another. We found some damage around the belly band, and gobs of silicone, which is an indication of other problems.

Pulling the belly band off revealed numerous rusted (some nearly gone!) mounting clips. Over time, these became holes under the band, allowing water to infiltrate. Thus the need for the silicone!

[Robert Johans]

The interior was not in any better shape than the outside — with some evidence of FG cracking to the internal forms. So we removed everything held down by a screw.

Of course, as is the case with nearly every restoration, this trailer had 35+ years of nasty dirt packed into every nook and cranny.

However, the Ensolite was in surprisingly good shape — no tears or holes — just a few spots where the plastic seam covers were missing.

[Robert Johans]

After everything was removed from the interior, we tried to clean as much as possible. I started with scrapers, wire brushes, solvents and the vacuum, then followed up with the power washer.

After everything dried, another pass with scrubbers, brushes and the vac.

It was now as clean inside as I could make it.

[Robert Johans]

The plan was to not only paint the outside, but the inside as well. But the inside would get a bedliner-like texture coat. This would help to hide the few flaws in the FG as well as freshen the look of the old Ensolite.

Of course, just like the exterior, this would mean FG repairs to the interior components — filling all old holes and superfluous cut-outs. Plus some judicious use of caulk to help hide some of the Ensolite seams and problem areas.

Here you can see the shell stripped of old paint and some of the body work, including the belly band.

[Robert Johans]

We found a paint color that was nearly identical to the original gel coat color, but decided a contrasting color to the top shell would be great.

While the shell was being repainted, we had the frame sandblasted, inspected and repainted. The axle was still in good shape, but replaced the original hubs with new drums with 10" electric brakes.

Check it out.

[Robert Johans]

I was very impressed with the results of the interior paint with texture. Amazing transformation!

Again, the furniture and walls were painted with the bedliner-like paint. However, it was thinned down to a degree that the texture is very similar to that of the Ensolite. Quite soft. So, on the walls, the texture is not noticeable, but hides all of the old flaws.

I am so thrilled with the look that I intend to repeat this process on every other restoration coming out of my shop in the future.

[Robert Johans]

With the paint now complete and fantastic, I turned my attention to the rough install of the electric and gas concerns.

There's never enough storage on these little trailers, so I found this great cargo container for the front. The shape does not work with the Boler body style, but fits well with the more square-cornered Trillium.

The storage box gave me a place to hide the propane tank and the emergency break-away control battery.

Of course, there's lots of other room for hoses, tools, etc.

[Robert Johans]

You might have noticed the Tekonsha Prodigy RF Brake Controller mounted to the side of the frame rail. In front of it is the emergency break-away switch, and behind it is the two-stage regulator for the propane lines.

Also notice the solar panel "quick-connect" from Zamp Solar.

[Jim Bennett]

I just picked up a 76 Trillium 1300, that will be a project trailer. Seeing this thread, I am getting lots of good ideas, and have a few questions.

I like that box, where did you get it?

Are you putting a rock guard on? Mine does not have one, and will either have to build, or buy, one. Otherwise water ingress while driving in the rain would surely be a problem.

I like the cleanliness of putting the propane regulator where it is, but are you not concerned with it getting damaged there?

[Robert Johans]

On the curb-side of the storage box, we added a 110VAC plug, in case the client wants to hang chili pepper lights from her awning...

Of course, we couldn't put the old inlet/outlet fittings and hardware back on the new paint, so new ones were sourced and installed.

And new LED lighting all around...

[Robert Johans]

With the front end wired and plumbed, I moved to the inside to continue with the electrical.

The 7-pin harness from the tow vehicle connects to the Prodigy Brake Controller on the frame. A shorter 7-pin connects the Controller to a buss bar installed inside the forward street-side storage bench. From the buss bar, power from the tow vehicle is distributed to all of the DOT lights, and separately to the on-board AGM battery. (The AGM requires no maintenance, nor venting.)

Via separate connections, the AGM is also linked to the break-away controller, the solar "quick connect" and the converter.