68 Overlander – Fitting the new inner skin

A new inner aluminium skin is being fitted. We are using skin pins to hold the panels in place while rivets are fitted, but its still a two person job. Fitting the skin will require over 1000 rivets.

68 0verlander – External Skin Repairs

There were several holes left by the removal of the old furnace and water heater. I have patched each hole with matching aluminium. Once the new rivets are ground down and the patch polished the result is quite pleasing and I think reveals some of the history of this airstream.

68 Overlander – Floor and Insulation

With the chassis repaired, cleaned and painted the insulation can be fitted. I am using  25mm cellotex fitted between the chassis rails with the edges taped to protect the top of the chassis from any water trapped under the floor. 

Here you can see the insulated tub in the new rear chassis which houses the grey water tank

The new flooring being fitted is 18mm phelonic plywood. Waterproof and very tough.

68 Overlander – Polishing stage 1

Removing the clear coat has revealed a very clean skin, largely protected from oxidisation. The first stage polish, using a course polish and a stitched mop generates a deep shine – and a lot of black muck!

68 Overlander – Stripping the clear coat

Before the skin can be polished the old clear coat lacquer will need to be removed. I am using a water based paint stripper which is applied as a gel and after allowing time to react is removed with a pressure washer. This is a environmentally friendly product so the residue is harmless.