And the outside renovation has started.

[sjweave]

After a year of testing the mechanical, structural and everything else in between integrity on our 1995 Damon Challenger 3300, it has proven itself worthy of upgrades.
Being the third owner and having all of the records from the PO's helped in us deciding to purchase it. 40k miles, all appliances and accessories have been replaced or upgraded by the PO's.
The inside needs updating but is in excellent shape. The outside needs the most help and after the midlife check on the transmission came back with 5 stars and with the few maintenance items on the 460 engine complete......we have started.
There is minor delamination due to some window leaks, a drivers door leak and failed seals around some lights and an electrical outlet. Using West systems G-flex to straighten all of that out. Will be removing all of the windows to lay in fresh butyl tape to prevent anymore issues. The windows and all seal points will also receive an outer bead of sikaflex urethane as a secondary seal point. The graphics will be gone over.....some removed and replaced, or trimmed up and cleaned up. Then the scrub down will begin for the final coating of Zeps wetlook.
Including some pics of the steps taken in handling our biggest delamination area.

Open everything up around the area to get and idea of the extent of damage....not near as bad as I thought.

Test fitment for my press.

Masked off area in preparation for the epoxy injection.

60ml syringes used with 3/8 inner diameter and outer diameter to inject and wet out the panels.

Epoxy injection complete and press is in place. Will let this set until the next morning then move on to the next one.

[sjweave]

Meant to include pics to show what we are starting out with.

[Bad Bolt]

Good luck with all the repairs and updates. Looks like the coach is worth the time and expense.

[sjweave]

Thanks Bad Bolt. We had looked around for almost a year when this one came up. Previous owner was retiring and moving to Florida and after three asking price drops he called and said to make an offer. Was able to get cash out and title in hand. According to the blue book value we got it for less than half the listed value. This is our first to see if it's something we would enjoy and it has been nothing less.
Our biggest issue is not rushing our planned work to get our season started 😁.

[sjweave]

Attachment 158860
Attachment 158861
Press is off and I'm satisfied with the result. I've probably should of rollered the panel a little more aggressively to help flatten and spread. This is the first time I've used G-flex and it is thicker than most epoxies for this application, but the recommended one designed to be flexible enough for the "mini earthquakes" driving down the road.
I had two small areas that the epoxy collected in pockets and left little bumps. Not noticeable without really looking hard down the side, but with the thicker consistency extra care will be needed in spreading it out.
Also....lol....I figured with the thicker viscosity I wouldn't have as much run out when injecting over head (top of window). I was wrong, elbow length gloves would of been perfect.
Fortunately this was the biggest area of issue and the rest will be alot more manageable.

[sjweave]

Pictures did not attach.

[sjweave]

Good my fellow RV fans 😁.

Today's project will be rebuilding a water damaged basement door 😨.

It started out like this one (pic below) but the window leak above it that caused the delamination (now repaired) soaked into the top rail of the door....after 22 years of opening and closing and caused water damage.


Removed it and took the outer metal support framing off.

The outer fiberglass was no longer attached and all the layers had separated causing it to sag and flex.

So now all that is left is duplicating all of the internal pieces then using West Systems G-flex to reattach all the layers together.

Then reattach the outer fiberglass skins with the epoxy also.
Hope everyone is having a great day 😁.

[Scarab0088]

I love seeing these older - but still very useable RV's getting a new life.

Best luck

[sjweave]

Thanks Scarab....so far it's been going well and no big surprises....lol.


New insides in place on one of two new luan backer plates.

Second lean backer in place that the fiberglass skins will adhere to.

The insides were pieced together in multiple sections and stapled. I made sure that each piece of wood or styrofoam was a single piece for more strength once bonded with epoxy.
All that's left now is to clean everything and sand the metal frames so they are etched to grab the epoxy.

[sjweave]

Rear basement door has epoxy and is now being pressed.

Removed the second window that leaked....epoxy in place on the inside and outside panels. This one took a little more planning than I initially thought. Had to build an inside and outside press and make sure I didn't flex the wall as I squeezed the two together.
Hope everyone else's projects are going smoothly as I've enjoyed keeping up with theirs also 😃.

[Bad Bolt]

Very nice progress!

I am going to get my new 67 Winnebago F17 to my brother in laws this weekend for him to go over the chassis, engine and fuel systems to make a good and safe rolling project.

The unit is gutted and needs extensive repairs on the roof and inside. Should be a blast to rebuild this classic to modern design.

[sjweave]

Originally Posted by Bad Bolt

Very nice progress!

I am going to get my new 67 Winnebago F17 to my brother in laws this weekend for him to go over the chassis, engine and fuel systems to make a good and safe rolling project.

The unit is gutted and needs extensive repairs on the roof and inside. Should be a blast to rebuild this classic to modern design.

I look forward to following your progress on your new project 😃.
It's good timing on your post....I just got home from an errand and just saw a Winnie Brave (looks like a 70's model) that's for sale on the side of the highway....and your new project came to mind.
Was going to get a few pictures of it for you but was in traffic.....and the wife was rolling her eyes thinking I was mentioning it as another project...lol. Next time I get gas I'll roll in and get a few pics.

[sjweave]

Do to extensive overtime and torrential rainfall....lol....I've been away from our project. I'll update the slow progress though. Passenger front window is back in and resealed (just in time for the rain).
Will take a pic of the finished install once the rain stops.
The basement door rebuild is complete and ready to be reinstalled.....before and after pics below.
Before: With severe water damage.


After: After duplicating the internals and luan, reusing the inside outside metal rails and fiberglass skins. Pressing back together with West Systems G-Flex.

And finished:

[sam-3]

Looks like you are doing a great job. Keep up the good work. I can appreciate all the hard work as we had water damage on our 1990 25ft. Classic HiLo. DH used a floor roller to press together layers of wall wood,paneling,and foam. Another good caulk to use around exterior windows is Lexel caulk. It is about $8.50 a tube..worth the $. Can be found at ACE hardware.Lowes or on line. Love the pictures. We are all get hammered with rain and Tornado warnings. Will need a boat lawnmower at the end of the week.