We have big news! Our new subfloor went in this weekend and it’s pretty damn exciting. It wasn’t as hard as we expected, but it was still kind of hard. If that makes any sense.
We started the weekend on Friday with priming all of our plywood with Clear Penetrating Epoxy Sealer™. We had already measured (re measured) and cut the pieces we needed. We initially used cardboard to make a template of the front cornered piece. The cardboard was a good idea because we could measure and trace around the C-Channel and get a good measurement for the curves. We made sure to put a heavy coat of Epoxy Sealer on the cut edges. It’ s edges that are most vulnerable of course.
We first placed the cardboard template (front corner) where it needed to be. Of course, installing a piece of cardboard is much easier than a piece of plywood. The cardboard looked like it was where it was suppose to go and we were happy with our measurements. Maybe a “good nervous anxiety” is a better expression.
TIP: Double check, and re-check, that all of the tiny wood screws that get drilled in at the top of the C-Channel are OUT. This will save you from pulling your hair out and having a break down in front of loved ones.
Saturday was spent on the front Belly Pan. We wanted to make sure that before putting in the Subfloor, we could see the new rivets going in to secure the Belly Pan. With my new Central Pneumatic 3/16 in. Air Hydraulic Riveter we were ready to tackle our Belly Pan. We drilled out all old rivets that the belly pan had dropped through. Surprising, our Belly Pan is in pretty good shape. We did drill new holes in the bottom frame using a 3/16 drill bit and popped in 3/16? Large Flange Rivets. Some places in the Belly Pan the holes were just too big. So we used large Fender Washers with the Large Flange rivets to secure and cover the holes. We also cleaned and prepped the frame once again, along with touching up any spots we may have missed with POR 15. By late Saturday we were exhausted. Sleeping in a 1998 Ford Expedition with 2 dogs on a Air Matress can be cozy, but we were so tired on Saturday Night, both dogs and humans were fast asleep by 9:30 PM.
Sunday: (The big day). Woke up early to a blue sky and the Rooster crowing. After mayhem with the dogs and few cups of coffee and a brief visit with Tulip the Goat, we were ready to get that floor in. We opted (after long debate and discussion) NOT to have any insulation between the Belly Pan and the Subfloor. But we did opt to using a Self Adhesive Waterproof Rubberized Asphalt Roll Flashing. This protects the Frame and the Plywood from moisture that could get in between. The Flashing also protects the Outriggers that are most vulnerable to the elements. After taping the top of the frame, we were ready.
The funny thing about putting in the first piece of your new subfloor was; “Are we really here”? We were almost in denial looking for other things to do before we actually put this in. With some trepidation, we brought in the front corner piece. We had cut some 2×4’s that we placed on the frame so we could beat the 2×4’s instead of the plywood. We brought in laying it down on the frame but on a slant. The “idea” here, was to push the out one side of the C-Channel and then to beat the front piece using the 2×4’s. Once we got both ends in the C-Channel it was then a matter of just beating it forward all the way in the “front C-Channel”. To our amazement, it worked. However, the rubber mallet was quickly replaced with a sledge hammer. (*Side Note: When something goes right on our Airstream restoration, we ask ourselves, “is this real or a dream”?)
TIP: Be prepared to beat one side of your Airstream to move the “cut” from right to left. Use a 2×4 for this also. Remember, you are pushing out one side of your C-Channel to get both ends in the C-Channel.If your cut is correct, the one side that you pushed out, will come back in.
The next section was only 2 feet wide to sit on the frame correctly and get bolted into the Outriggers correctly. That piece went in fairly smoothly.
The 3rd piece, (the biggest piece) was 4 feet wide went in by lifting the “cut” up over our heads, tucking the far end (opposite of the door) into the C-Channel, then bringing it down and tucking in the other end. This also involved major beating on the side of the Airstream.
So, the first 3 pieces are in. 4 more to go…