Rebuild of a Trillium Sportsman

[Francesca Knowles]

It's been this Junkyard Dog's experience that "metal recyclers" who take in everything from old appliances to old lawn furniture are the most fertile ground for trailer scrounge.

As Ryan indicates, many auto wreckers won't mess with RV's, especially old trailers- but scrap metal guys will. Gotta check them out regularly, though- they don't wait long to put things in the compactor!

Francesca

[ryan parsons]

A couple of pics I said I would post first is front window reinstalled pic from inside.

the next is of the two fridge vents and the junkyard range hood

I marked out the rear side windows just before it got dark and should be will be able to hide-cut out the patch from previous owners. That patch was covered by the mysterious grate that vented nothing, picture of that grate on What is this thing thread, before this rebuild thread started.


the other side is marked out also. Next will be the fridge vents and side compartment doors. Hopefully all tomorrow.

[ryan parsons]

Just about got what was planned one. Two windows installed 2 fridge vents installed and a bonus Fed Ex delivered my ceiling vent I purchased from Adventure RV so temporarily put that in to.


Window rough in was easy just used my Zip disc and marked hole size then cut them out, Put 3/4 inch buytl tape on windows then slide them in the hole clamped interior window backing to window, predrilled the holes and mounted them using #8 x 1 inch stainless round head screws. just snug enough to squeeze out a little buytl. I did the exact same thing for the fridge vents measured through existing holes to find cabinet then marked and cut, the upper iI put it so the lower louvers are 1 inch above top of coils. Was real good to get rid of all those old holes for whatever was in them.


Temporary trim boards for attaching new vent will make a trim ring stained to match window trim boards. Well that was it for today. Have to work tomorrow so not much will get done on the Sportsman.

[David Tilston]

Kinda looks like a cross between a Trillium, a Surf Side and a toy hauler. Amazing thread! I look forward to more updates.

[ryan parsons]

I really wanted triple glass jalousie windows for back as it was a standard on them. I couldn't find two of them anywhere that were at least 30 inches wide. The double pane windows are what is on Surfsides so a little bit surfy side looking Well off to work might get something done this evening on the [COLOR="Green"][Thrillside/COLOR]

[ryan parsons]

Started to put and finalize the upper front cabinets I roughed in last winter. They is quite a bit of patience involved in getting a good fit.
I thought maybe that I should show the process of getting them to fit. I first cut cardboard templates to match the wall angles. I was only interested with the curvature for the initial cardboard templates, then the vertical straight edges after the curvature was right. I needed good cardboard sheets that were stiff enough to be held in place without the floppy thing happening so I used a cover sheets from lifts of russian birch plywood which the building supply donated. I trim the cardboard to a usable width about 20 inches x 4 ft cut a real rough curve on the end and then using a compass scribed the fit and kept this up until the fit was real good for the intended curve. I attached pic of some of the templates


The second picture shows a upper left cabinet base and the template used to get it (mirror reverse) I only used the template for curvature as straight edges are relatively easy to accomplish once the curve is done. Because the base is 1 inch thick, a final curvature (backcut) had to be put on it to fit the assending curvature.

I then had a width that was to big but the curve and other end fit great,then squared off backing and marked for outer face for shelf and the cut to final size as you see in picture

the next picture is that shelf in place with outer skins cut. The depth is little to big but fit on curvature and outer end is fine, just have to trim with saw. I will be putting holes in flat panels for cupboard doors, but will router them in before final assembly.

Tomorrow is the big day when the front uppers are completed. I will of course put another addition to the thread tomorrow.

[Francesca Knowles]

You're making me ashamed of myself, Ryan. I've been dithering for a month over how to install a teeny shelf over the sink!

Gonna get right on it...tomorrow...

Francesca

[ryan parsons]

Francesca you can bring it up. Then we both can dither about it a bit then we can get it done. lolwu
Ryan

[ryan parsons]

Saturday is now done for me, Had one heck of a bunch of fitting today in the front right and left upper cabinets. I was well worth the effort, the last trailer had only standard Boler cabinets on the top so not much storage in them. Now we have UPPERS- big ones, lots of room.
I had the backing already glued to the fiberglass and the plywood pieces rough cut so it was just making them fit and adding a sub frame for the plywood to glue to and doors hinges and locks to screw into the first picture is of the one subframe the next with the corner plywood in place but not nailed just tight fit. I eventually glued (waterproof Glue) and wire nailed them (22 gauge wire nails)


The next is of the front panels all attached and the next is pilot hole for flush cut router bit to fit in.


The finished holes all that is left on these is corner trim and that is going to be dark stained douglas fir outside corner trim 11/16 x 11/16

The right side done the same way as left, you can see one of the wire chases on top of door. I will put removable cover on it after all the wires are run.
Had enough time left before I got fed up today to glue in backing pieces in the rear corners for the rear vertical cabinets (fishing rod closets)


Sunday will tackle those two closets and maybe the side uppers. will post again tomorrow
Ryan

[kootenaigirl]

Your reno is so impressive! Love seeing the updates and can't wait for the end result.

[Francesca Knowles]

You know, Ryan, I'm beginning to think that you entitled this thread wrong!

The Sportsman came off the line bare-bones- no interior finish at all. It was up to the owner to finish the interior....and in this case it seems to me that's exactly what you're doing, albeit more than thirty years later. (The rough finish somebody else plugged in in the mean time notwithstanding)

I hereby rechristen this thread
Trillium Sportsman: The Way It S'posed To Be!



Francesca

[ryan parsons]

Yea haw we had a hot day today its presently 29 C outside in f its 84, for you southern folk. Not hot for some but hot for early May. I didn't let it deter me from what had to be accomplished today, the rear corner cabinets and start the top side uppers. above the bed. I started by of course making a template for the right side. I had to make it in two peices so started with the top first.

I used a compass to scribe the profile trying to keep it 90 degrees to the trailer surface. Then cut and refit and then rescibed and cut and refit until it was good.


Then took another sheet of cardboard and did the exact same thing to the bottom half.

Then put both into there spots and taped them together that gave the wall profile. next was to mark the 1/2 inch plywood and only cut the curved surface not the straight edge and then refit. I cut the curved edge at 30 degrees as the daminishing angle was different the whole way up, 18 degrees in spots 28 in others so 30 degrees would give the clearance needed for the leading edge to fit. The plywood was over size by at least 4 inch in width,



leaving it over width is so it can have a final fitting and then I cut the straight edge with a guide nailed to waste side as it was not even with the final position. Then after some time I had the blank and only had to put a 1x1 frame on the inside so router had a guide and then had a door opening then sam procedure for left hand side I just tweeked the right side template a little so it was quicker to do


Then it was all done and screwed into position and that took 7 hours to do so got a little more done but out of picture room on this post.
Ryan

[Francesca Knowles]

It was in the eighties here, too, so...I went to the beach.

But while I was there I thought about getting my projects done!

Francesca

[ryan parsons]

The other stuff done today was the side upper backing bottom done

the backing has polyurethane construction glue on it and needs overnight to set so the clamps are holding a pry board so backing stays tight to fiberglass.
Also fit the front counter top and propped side extention into position. Then it was beer time and dinner.

Tomorrow, if time fit the face of the side upper and if no time for that, start the wiring. so we have taillights also inside lights etc. My Bride got the curtains underway today and the new upholstry fabric was bought and tomorrow she is going to get the foam that we don't have now, we are recycling some of the old foam from before as it is like new. it is to bad most of the old foam is to narrow to use on this project. We still plan to use the trailer the May 18 th weekend finished or not.
Ryan

[David Tilston]

I am impressed! It looks like by the 18th, you may have a workable trailer.

One question. You removed 550lb of material when you gutted it. Do you have any idea how much weight you have installed? Just wondering what the final weight loss/gain you are expecting.

[GMike A]

I probably asked before but specifically which router are you using to make your cuts. It seems when every I cut a rectangle or square it looks like I had a quart of rum before I started.

[ryan parsons]

Monday and the only thing done on the Sportsman is that my bride ordered the foam for the bed and the curtains are being made by a friend of Debs.
So David you asked what is the weight plus or minus of the 550 lbs of plywood when done. The final scale weight will tell but I am thinking now 175 lbs lighter with way more storage, less floor room and less seating more counter space and storage, Have we got storage. Also have fridge not icebox so that weight I think is 85 lbs and the ice box might have been 20 lbs. Also eliminated the water tank which was 14 gallons imperial the weight empty is 12 lbs,. The microwave will be eliminated but we are making a space for it in case we want it later. We are using a little less 4 inch upholstry foam and adding a 6 inch foam bed so that will weigh more. But apart from all the figuring I won't know until it goes across the scales and I will post the weight when done, I promise, it may just be in my head but I think it will weigh 175 lbs lighter.

[ryan parsons]

Mike it is a Porter cable 6902 1 3/4 hp router. I have used that model for 30 years, they in my mind are the best in there class. The blades are the most important part, use a good blade get a good outcome. Sometimes mine don't turn out so good too, but a good bottle of rum makes bad cuts go away a least until the next morning. LOL\
Ryan

[ryan parsons]

Wednesday- man did it fly by, The uppers both sides all boxed in ready for edge trim and will make all the doors later



I made rear side uppers the same as front- 1 x 1 frame attached to backing on ceiling and glued and screwed to bottom board, in the case of the side rear uppers the lower was 1/2 in Birch Ply, the front shelf was a 1x1 frame with 1/4 in birch ply glued to it.


the 1x1 plates are glued nailed and screwed to the few verticals, need them strong.
I was going to put in a rear center and front center uppers in, but that has to wait a bit as wiring has to be next and staining some edge trim and making window and ceiling fan trim boards.
I am running out of time, the 18th is coming fast. I am hoping the curtains are done by the weekend and have to get the flooring Friday.

[Donna D.]

It's been often said, if you need something done... find the busiest person on the team... they know how to schedule time! Ryan, you've done amazing work and IMHO in short time. THANKS for sharing the journey with the rest of us