Belly band replacement on a Boler

[Shanos]

I'm reaching the finish line on a rather extensive renovation of my Boler and I've reached the point where I'd like to replace the aluminum belly band. I wasn't able to save the old one so I'm wondering what is the best/easiest way to replace that. I see that Scamp sells 7'6" lengths of belly band. Any other products available? Thanks for sharing any information!

[FRED SMAILES]

Hey Shannon, have you checked around for aluminum extrusion companies in the L M?
Aluminum channel close to the bolers probably hard to find, maybe a 1x1 aluminum angle could be shaped to work?

[Shanos]

Hi Fred,
Thanks for your reply. I'm not exactly sure what I'm looking for. The trim that they sell at Scamp seems to be soft enough to bend around the curves. Hard to imagine how that works without it buckling. Just wondered if anyone has had experience actually bending it.

[Glenn Baglo]

The aluminum part of the belly band does not conform exactly to the trailer on my Escape, but you don't notice unless you are laying on the ground. I would think you could find that channel band and form it to your boler. Have you tried Fraserway RV?

[FRED SMAILES]

Snannon, heat is your friend,,,lol.

[steve67]

I have a band that I took off and am not using, but it's a bit far and awkward an item to ship. Too bad, you could have it if you were near.

[Shanos]

Hi Steven, thanks for the thought though! I would have appreciated that! I'm sure I'll come to a solution

[Shanos]

Hi Fred, yes, I was thinking a bit of heat may be required!

[Markz]

I created a jig to bend the 3/4" Home Depot channel. Bent four peices to wrap around the camper and pop rivited every inch or so. It takes time, patience and alcohol.

[Shanos]

Hi Mark, thanks for your reply. What sort of jig did you make to bend it? Did you pop rivet the top or bottom…looks like the bottom from the photos?
The channel from Home Depot must be very soft to be able to bend it
Your trailer looks Amazon btw!
Thanks,
Shannon

[Markz]

I pop rivited on the top.
I made the jig by tracing the body curve onto a peice of 3/4" MDF, cutting it out and sandwiches it between two 2x4s.
I used the cut out peice of MDF to press the 3/4" C-Channel into the curve using large C-Clamps.
Go slow with patience, and practice a bit, as it is easy to crease the C-Channel in an undesirable way. Buy extra material. Good luck; Results will vary.

[Shanos]

Great idea Mark! I was thinking of curving over top of a convex form but your idea to sandwich it to prevent kinking makes sense. Was it necessary to have the rivets so close together or was that for esthetics?
Thanks again

[Markz]

A bit of both. The jig idea is not originally mine. I got the idea from another member to this board.
You can find anything here.

[Markz]

If I would do it again, I would sandwich the mdf between two peices of aluminum then the 2x4 wood for support.

[Shanos]

Hi Mark, thanks again for your thoughts on this. Why would you use aluminum first? Harder than the 2 x 4's? I'm going to tackle this job in the next few weeks I think. Sounds like the key is to support the channel and go slow!

[Markz]

Originally Posted by Shanos

Hi Mark, thanks again for your thoughts on this. Why would you use aluminum first? Harder than the 2 x 4's? I'm going to tackle this job in the next few weeks I think. Sounds like the key is to support the channel and go slow!

Yes, harder then the 2x4 thus more sidewall support. On my gig, the 2x4 sidewalls were getting pretty chewed up and providing less support over time.
Please note, I plained the Cut-Out MDF wedge to fit snuggly into the C-Channel. Make sure yours does.
I know my original bending method worked, however, on my next build I will try my aluminum sandwich idea first.
Please let me know how it works for you.

[Shanos]

Hi again Mark,
I've got my form made for the curve. I'm thinking that you use half of it a time to avoid bending such a large curve in one go. Also, in terms of where you start clamping, any tips? Start at one end and move to the other? Do a little in the middle first? I've got extra
Thanks for your help!

[Markz]

I started from the beginning point of the curve and worked my way through it.

Notice on my gig I placed arrows. I found that if you always use the gig in the same direction the results were more uniform.
Just take your time.
Please show us a picture of the gig you created.
Attachment 146499

[Bayou Belle]

Originally Posted by Markz

I pop rivited on the top.
I made the jig by tracing the body curve onto a peice of 3/4" MDF, cutting it out and sandwiches it between two 2x4s.
I used the cut out peice of MDF to press the 3/4" C-Channel into the curve using large C-Clamps.
Go slow with patience, and practice a bit, as it is easy to crease the C-Channel in an undesirable way. Buy extra material. Good luck; Results will vary. Attachment 146023Attachment 146024

That is BEAUTIFUL!!!!!! What sealant did you use, please?

[Markz]

I didn't use any sealant. I had previously sealed the belly band halves with resin. Now the aluminum channel is pressed tight against the lip further preventing and water intrusion.