Trailer lights

Yesterday I worked on the trailer lights, they were in really bad shape but I have both original tail lights and three out of the four original KD-540 running lights.

As you can see the bases are completely rusted out. There are reproduction bases for the KD-540 but I cant afford them right now so I decided to make my own.

First I had to find some light sockets that would work, I got these for $2 each.

Then I traced the pattern from the trim piece.

Then I put the cutout up to the side of the camper to locate the holes I needed to drill into it.

Then I rivited the bulb socket to the cutout.

Not as elegant as the reproductions but it works.

Next I screwed the new bases to the camper using stainless screws then attached the lenses.

Once I find some flathead stainless screws I will replace the phillips head ones.

I ran all new trailer wiring to all the lights. I didn't get a chance to finish installing the Bargman no. 2 tail lights but I did get them and the new center license plate stop light wired up.

I also finished up on the tongue. First I sanded it down with a wire wheel.

Then I sprayed it with a rust inhibiting sandable primer.

Then I sprayed it with a high strength enamel gloss black paint.

New Trailer Coupler

The original trailer jack was in bad shape and missing the crank. I decided to go ahead and replace the jack and the coupler.

First I removed the propane rack, the bolts were frozen solid so I cut them off. Then I cut the rivits off that hold the jack on. I had to free up the jack to remove it because the jack has to come out the bottom.

I was able to remove the eight bolts holding the coupler on.

and then remove the coupler.

The new coupler did not have any holes so I had to set it in place and trace the holes out from the inside. Then I drilled the holes into the coupler and installed it and the jack.

Tomorrow I will take the coupler back off, sand the tongue down with a wire wheel, then Primer it with a rust inhibitor, and then paint it.

Bolting Down the Shell

I spent the day bolting the shell down to the floor and frame.

I used 1/4"x2" carriage bolts with a flat washer, lock washer, and nut.

I have a few that were in awkward places that I still have to tighten by hand. I also need to finish bolting the floor to the frame.