Repairing the door openings

The door openings were in really bad shape. Every piece of wood in both door openings was rotted and some of the aluminum in the rear door opening was corroded and falling apart.

I started on the rear door. Not sure why but the rear part of this door frame is built differently than the rest. Their is an added curved piece of 3/4" wood that makes up the part of the frame instead of just an aluminum piece of framing like the rest are.

Here is the curved piece of wood. You can see how rotted it was, I'm using it as a template.

The new piece of 3/4" is pressure treated. Here is the piece installed.

With the framing installed I turned my attention to the 1" plywood strips that make up the door stop. Here is one of them after I cut it to fit.

The next thing I had to do was repair the corroded aluminum at the bottom of the door frame.

You can see the new pressure treated framing piece and the 1" strip of 1/2" plywood behind it.

First I cut the old piece just above where the corrosion ended.

I was able to make somewhat of a template out of the corroded piece I cut away. Then I bent the new piece into shape. This took quite a while. I had to go back and refit it into place then take it out to make adjustments.

Once I had the piece shaped properly I riveted it into place.

Once it's cleaned and polished it shouldn't be noticeable.

 Then I nailed the aluminum skin to the plywood strip. The plywood strip is nailed to the piece of 3/4" wood.

Next I worked on the front door. I replaced all of the plywood strips and secured the aluminum skin to them like on the back door but I didn't get any pictures of this.

The next thing I did was install the new door handle on the front door.

First I used my template to trace out where the hole will be cut.

Then I cut the hole and installed the new lock.

It's supposed to rain some this afternoon. I hope it rains a lot because this should be my final test for leaks (I hope).

If all goes well I should be able to start installing the floor soon!

Rear Door Lock

I scored three sets of Bargman L-66 door locks for $100 at a small RV shop. They are used but in perfect condition. One is a complete set, the other two have a few parts missing.

I was able to make another working set out the the two minus the interior locking mechanism and a hold down bracket but I was able to replicate both out of some metal I had. I'll try to get some pictures of that later.

The set that was missing pieces had a set of keys with it but they dont work so I'll have to get a new tumbler set for it. I installed it on the back door so the complete working set with keys can go on the front door.

The measurements for the rough opening are 7" x 2 1/4". I used a scrap piece of acrylic as a template and used it to make the mark on the door.

I cut it out with a jigsaw then installed the lock.

It's going to need a lot of adjusting to work perfectly.

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.

Rear Taillight

I got some new stainless bolts and test fitted the new license plate bracket/stoplight.

I'm hoping to get a lot of work done on the camper this weekend.

Parts - License Plate Tail Light

I've been really busy with other things since bringing home the trailer but I have been ordering everything. I'm hoping to begin work today.

One of the things I ordered is a really cool third tail light. Spartans have a third tail light mounted to the license plate bracket. I bought a new stainless bracket since mine was completely rusted and broken. Then I found a stainless stop light made for 40's hotrods.

Turns out both parts are made by the same company and fit perfectly together.

The light is made of stainless steel and uses real glass. stop is amber and the rest is red.

I cant wait to mount this on the Spartan!