Manky Monkey Motors

OK, as promised, here we go!! This’ll be a bit like American Hot Rod then,  build an “Airstream” camping trailer in one night!!

Right once a size was decided upon, a drawing was made on the floor.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32005_640_x_480.jpg)


2”x1” box was then pie cut and bent to give a basic chassis level outer frame.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32006_640_x_480.jpg)

This system was used on the opposite side and a couple of right angle lengths to carry the suspension units (from a speed boat that I built a new trailer for, but that will be another story) and some cross bracing and this is what we had ……………

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32008_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32009_640_x_480.jpg)

The hitch was then added and checked to make sure the trailer was level with the car (anal, I know but that’s how I work, attention to detail).

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32014_640_x_480.jpg)

From the chassis, some 1” square uprights were added and an 1” frame to mirror the chassis ,loosely fitted.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32015_640_x_480.jpg)

On to the floor. It consists of a fibre glass/exterior ply sandwich. Reasonably close by is a company that manufactures endless fibre glass sheet. This is about 9 or 10 feet wide, and if they get a “blow hole” in it, it’s discarded in their waste bin. So guess where all the interior came from, it’s quiet round there on a Sunday !! (only problem is, you have to go with what colour is available).
So a sheet of fibre glass then a sheet of exterior ply and then another sheet of glass fibre.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32024_640_x_480.jpg)

Then all the inner panels cut and fitted.


(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32026_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32027_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32028_640_x_480.jpg)

Inbetween the uprights 1” thick polystyrene was used as a filler. Then the aluminium outer skin was attached using special rivets (Airstream repair rivets, they’re easier to use to bucked rivets).

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32029_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32035_640_x_480.jpg)

So this what we ended up with for two or three years, without a top!!

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture026_640_x_480.jpg)

Now, a bit fed up with having to wrap up all the camping gear in a tarp to protect it from the rain etc. We needed a top.
The frame had already been fabricated to match the top rail and the boot hinges from a 100E grafted on together with a pair of gas rams from a Rover 820 boot lid and a pair of door catches from a Vauxhall Corsa!!

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32032_640_x_480.jpg)

Also a Fiesta boot lock assembly to unlock the top, and some framework to support the top cladding.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32051_640_x_480.jpg)

It then had to be clad to give the look of an Airstream. The late ‘50s style, called the Dutchman was chosen to clad the top. This consists of a main top panel and 6-8 panels (3-4 either side) to finish it off.
So to start with (we’re working backwards here) the top panels are cut and shaped and fitted temporally with “clicos”.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture063_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32048_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/hotrod32047_640_x_480.jpg)

Then shaped (curved, all Airstream panels are flat and are curved to give the shape, not wheeled) panels are added until the top is covered.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture065_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture070_640_x_480.jpg)

Now this is where the problems start!! This is the area left to fill. On a full size trailer the curve radius is quite large. On this, it is fairly small, so we need to fabricate something to fit in.

 (http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture073_640_x_480.jpg)

So with the help of a good buddy of mine from the Santa Cruz area of California, Ron Covell  http://www.covell.biz/  and Fintan Ellis  http://www.fhellis.com/  a solution was hatched.
The area that was to be covered was filled, to the right shape, with fibre glass laminate.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture077_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture079_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture078_640_x_480.jpg)

Once that had “gone off” a mould of the area was taken and some strengthening was added.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture080_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture081_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture082_640_x_480.jpg)

Once this had hardened. The strengthening was clamped in a vice and annealed aluminium sheet was beaten into the mould. This is called Hammerforming. Once the four corners had a rough shape they were then further shaped with the aid of an “English Wheel” and this was the result (my first attempt at “Wheeling”).

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture083_640_x_480.jpg)

These were added to the top using the rivets.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture087_640_x_480.jpg)

And once polished, this was the result …………………………

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture089_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture094_640_x_480.jpg)

A couple of years back it was decided to change the wheels to match the roadster. The hubs were modified by pressing on a “donut” of steel to the rear, welding and machining to give a wheel mounting slightly further back than the original wheels.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture187_640_x_480.jpg)

The wheels were then trial fitted.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture189_640_x_480.jpg)

Once that was done, the centres that were supplied with the wheels needed to be shortened. This was achieved by boring a hole, the diameter of the centre, into a piece of hardwood. The trimmed centre could then be lowered into the hole and carefully peaned over at the required depth. The supplied one is on the right and the modified one on he left.

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture190_640_x_480.jpg)

Then finally fitted with new tyres, we were ready to hit the event circuit

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture194_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture198_640_x_480.jpg)

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/picture197_640_x_480.jpg)

Well, that’s it guys another little project finished.   ;D

(http://i781.photobucket.com/albums/yy95/phunkie_hiboy/Airsteam%20trailer/1274c16829d74a24_640_x_480.jpg)

Onto the next …………………………..

pure talant from a very talented man,,,

that is one very smart trailer

i have actually seen it  and its even better than the photo,s

Fantastic!

Lovely workmanship as always Chris.
Beats a wooden box doesn't it.

Very impressive i like it.

What skill and patience you have! The result is worth it though. Stunning!

Thanks for the comments, guys. Sometimes it's just a matter of thinking outside the box to make something a little different and sometimes unique   ;)

That's truly Awesome! Nice work.

Wat a bute great job