1978 Trillium 1300 restoration - Page 5 - Fiberglass RV
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Old 01-19-2024, 05:12 PM   #81
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front dinette continued

The remaining section of the bunk wall was formed by taping a scrap fiberglass sheet over the gap, then five layers of fiberglass mat was laminated in place from the inside of the bunk. After curing, the scrap fiberglass panel was removed and gaps were filled with Bondo Glass and sanded to shape.
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Old 01-19-2024, 09:09 PM   #82
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I appreciate you documenting your dinette construction. Its something I've considered doing with mine, but I'm not in a place to take that on quite yet.

You're getting pretty good with the fiberglass work, much nicer looking than my hack jobs. If I was to create the dinette, I would have probably built everything out of plywood to reduce the number of resin jobs.

My goal if I were to create a dinette would be to house the toilet or even convert into one when needed. The front bath model I have doesn't make a ton of sense in its layout. Interested to see how yours turns out

My build log is here if you're interested

https://www.fiberglassrv.com/forums/...log-97593.html
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Old 01-19-2024, 10:49 PM   #83
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Quote:
Originally Posted by AlexTN View Post
I appreciate you documenting your dinette construction. Its something I've considered doing with mine, but I'm not in a place to take that on quite yet.

You're getting pretty good with the fiberglass work, much nicer looking than my hack jobs. If I was to create the dinette, I would have probably built everything out of plywood to reduce the number of resin jobs.

My goal if I were to create a dinette would be to house the toilet or even convert into one when needed. The front bath model I have doesn't make a ton of sense in its layout. Interested to see how yours turns out

My build log is here if you're interested

https://www.fiberglassrv.com/forums/...log-97593.html
Alex,
Thank you for sharing your build log. I'll be going back through it when I get to interior painting, as that is something I have yet to do. Your finished interior looks great, how is the paint holding up? I think you mentioned that it may be better to go with a gloss finish over the Ensolite.
The nice thing about polyester fiberglass is that if I'm not satisfied, I can just dab on some more and sand again. Very satisfying if you're not in a hurry.
Fortunately, we also have a 4500 that we enjoyed renovating in Spring 2021 and is our pride and joy. This 1300 was meant to be more challenging and has not disappointed.
Cheers!
Steve
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Old 01-21-2024, 04:42 PM   #84
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Originally Posted by Steve Hague View Post
Alex,
Thank you for sharing your build log. I'll be going back through it when I get to interior painting, as that is something I have yet to do. Your finished interior looks great, how is the paint holding up? I think you mentioned that it may be better to go with a gloss finish over the Ensolite.
The nice thing about polyester fiberglass is that if I'm not satisfied, I can just dab on some more and sand again. Very satisfying if you're not in a hurry.
Fortunately, we also have a 4500 that we enjoyed renovating in Spring 2021 and is our pride and joy. This 1300 was meant to be more challenging and has not disappointed.
Cheers!
Steve
Appreciate it, thanks. I didn't mention that I ended up using polycrylic on the non-ensolite surfaces in the end. I wasn't sure about the durability of the finish, but the poly helped give it a glossier and smoother sheen. Sanded with the fine scotch brite before the poly, but didn't touch it afterwards. Poly sets up pretty quick so its best not to fuss with it (I used a sponge brush). The ensolite doesn't have much of a sheen but I prefer that over a glossier/plastic look.

So far no major scuffs, chips or scratches. I think a few areas where the cushions rub the ensolite they left a few marks but it doesn't bother me too much. Otherwise good as new.

If you had better airflow the finish might be a bit more level on its own and wouldn't require so much sanding. (I diluted the paint maybe 50-100mL per 700?mL cup). If the windows were out and I was indoors then it would have been much simpler. I'd still go over it with polycrylic though, just to be safe.

Eventually I plan on painting the exterior with topside like you mentioned. I had a boat place quote it and they gave me ~$4500+. No thanks, I only paid $6 for it!
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Old 02-15-2024, 01:07 PM   #85
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front dinette - another patch

These photos demonstrate the placing of a patch to replace a section of fiberglass that had been cut out by the previous owner.
This was just the first step in building up the fiberglass surface.
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Old 02-15-2024, 01:35 PM   #86
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Front dinette, curb side

Now to reconstruct the curb side dinette bench.
First step was to fasten a sheet of smooth fiberglass panel (with a plywood backing) in place to serve as the "mold". I then disassembled the mold and laminated several layers of fiberglass mat onto the underside of the mold and reassembled the mold. additional strips of fiberglass mat were laminated over the seam between the new section of the panel and the underside of the existing fiberglass. It was much easier, and far less messy, to lay in the fiberglass this way, rather than to do the entire process from the underside.
After curing, the mold was popped off and a piece of 1/2 inch plywood was laminated to the underside of the new and old panel for additional support.
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Old 02-15-2024, 01:48 PM   #87
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front dinette, curb side - continued

The inside wall of this bunk was fabricated from 1/2 plywood with fiberglass mat laminated on both sides, just as had been done for the street side bunk.
After clamping in place, it was secured with strips of fiberglass mat at all butt joints.
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Old 02-15-2024, 02:18 PM   #88
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front dinette bunk lid support lip

I was able to recover just enough original fiberglass lip to patch in where it was missing on the new bunks.
If you look closely in the first photo, you may see the three pieces that were recovered and cut to fit.
Additional strips of wood were added for support where necessary, then the pieces of fiberglass lip were secured by making a bed of fiberglass mat and laying in the pieces while the resin was still wet.
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Old 02-15-2024, 02:57 PM   #89
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front dinette, curb side bunk, continued

The remaining wall of the curb side bunk was fabricated by casting in place.
The first two photos show the mold in place. As before, the mold was taken apart and several layers of fiberglass mat were laminated onto the backside of the mold.
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Old 02-15-2024, 03:06 PM   #90
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The mold was reassembled with the wet fiberglass, then strips of fiberglass mat were laminated to the top, bottom, and both sides seams. After curing, the mold was popped off, revealing a glassy smooth wall.
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Old 02-15-2024, 03:22 PM   #91
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front dinette, nearly done

Lots of Bondo Glass was applied to fill in gaps and form the remaining support lip for the bunk covers and tabletop. Fiberglass mat was laminated over the plywood front bulkhead and floor and more Bondo Glass layed on to achieve a smooth surface. Much sandpaper was consumed.
Next step is gel coat, or perhaps straight to primer and paint.
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Old 02-17-2024, 01:58 PM   #92
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Quote:
Originally Posted by Steve Hague View Post
The mold was reassembled with the wet fiberglass, then strips of fiberglass mat were laminated to the top, bottom, and both sides seams. After curing, the mold was popped off, revealing a glassy smooth wall.
Bet that was a fun part, filling the back side of the fiberglass wall from inside the bench. My back hurts just thinking about it.

Looking great! When its all painted up, I'll bet it'll look like it rolled off the factory floor.
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Old 02-17-2024, 02:28 PM   #93
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Originally Posted by AlexTN View Post
Bet that was a fun part, filling the back side of the fiberglass wall from inside the bench. My back hurts just thinking about it.

Looking great! When its all painted up, I'll bet it'll look like it rolled off the factory floor.
Thanks Alex. I'm learning as I go. When I did the repair of the furnace hole in the kitchen cabinet, I laid all of the mat from behind with the mold assembled. But it wasn't too bad since I could do most of the work through the outside furnace vent hole. If I had taken the same approach with the bench wall repair, it would have been a literal pain. I have had to do some fiberglass mat lay-up to the underside of the kitchen cabinet and a little to the underside of the front dinette benches. I wish that I could have avoided this as it was a very messy, pain in the back.
Steve, fiberglass amateur in training
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Old 02-17-2024, 03:00 PM   #94
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detached Ensolite repair

Enough fiberglass repair for now, so I decided to start working on some of the loose Ensolite ("elephant skin").
The previous owner had installed a folding television antenna on the front curb-side roof. Of course, it leaked. I removed the antenna and patched the roof early on, but much of the Ensolite panel in that corner had already detached.
My objective now is to further detach any of the panel that I can, without undo damage to the Ensolite. Once that is achieved, I plan to clean the back surface of the Ensolite as much as possible, and thoroughly clean fiberglass wall before reattaching with contact adhesive.
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Old 02-17-2024, 08:32 PM   #95
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Bellyband repair from inside

I wasn't planning to start working on the bellyband for a while, but since I had just exposed a portion, I decided to take out some of the plates and patch from the inside of the trailer.
The multi tool made quick work of cutting out the steel plates. I taped the holes from the outside, then layed Bondo Glass into the holes. This should make the outside patch a bit easier and I won't have to worry about the pop rivet nubs poking into the Ensolite. I may laminated a layer of fiberglass tape over the Bondo Glass on the inside, but its probably not necessary.
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Old 02-18-2024, 08:15 AM   #96
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Tipsy Trillium

Did you notice the large gap between the top and bottom shells? The gap is 3/4 to 5/8 inch in this corner (front, curb-side). But the gap is not consistent, it narrows to zero on the street side.
When we did the bellyband on our 4500, the bellyband gap was even all the way around, I think about 1/4 inch or less.
I'm thinking that the assembly line was a bit rushed the day our little 1300 came through. Wonder what else I'll find. I already found that the kitchen was put in askew, dipping severely to the street-side, but more so than the bellyband gap. I expect that I'll find a challenge when I refit the door.
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Old 02-20-2024, 06:25 PM   #97
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reinstall T-molding track

There are many mundane projects that must be undertaken during our restoration. The original location of the track was masked off and contact cement applied to both the fiberglass hull and the back of the track strip. After the cement dried 15-20 minutes, it was carefully aligned in the masked area.
Another preparatory step was to coat the wall with fresh polyester resin to aid in adhesion.
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Old 02-25-2024, 07:43 AM   #98
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more loose Ensolite

Wandering from the front dinette area to the rear, decided to see how much more Ensolite needed to be re-glued.
Now I know. The detached Ensolite seems to be mostly intact, with a few small tears and screw holes that can be patched. One 3x3 inch area is missing the foam backing, but I think that I can find suitable replacement.
I took advantage of the exposed interior bellyband and removed more plates. I think that the remaining bellyband plates will need to be cut out from the exterior.
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Old 04-20-2024, 08:39 AM   #99
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Windows!

Time to move on to the jalousie windows. We pulled one out, tore it apart, and cleaned and polished the pieces. Four more to go, then I'll order new gaskets, a few replacement hinges, and perhaps a couple new regulators.
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