Phunkie Project Portafold (caravan!!)

[phunkie hiboy]

Those weren't the standard wheels poking out from under the masking paper though, were they?

 

it does strike me it might have easier to build one from scratch!

Problem is the moulds were probably destroyed along time ago, so new moulds would have to be made. They would have to be taken from a very good example, which because of the "light construction" would have to be strengthened a lot (and straighened!!). Someone had a quote to make new roof panels, so to make a new mould and make 10 it would work out at nearly £600 each. That was back in 2010 and materials have gone up alot since then, and the company was someone that made component parts for Sunseeker!!!

[Manky Monkey]

Fantastic workmanship Chris.

[DIZZY]

wow great thread and great work 

[phunkie hiboy]

Thanks guys.

[merv]

Whens the next instalment?

[phunkie hiboy]

Whens the next instalment?

We're working in real time now, so it won't happen as quickly as before(almost a complete rebuild in 2 days !!:o). Probably won't pos any progress 'till the weekend ,now. And we're at Basingstoke on Sunday (bloody shows always get in the way of suff like his). I'm even missing a "work in" on the Allard Chrysler 'cos of our event at Hartley Wintney on the 27th!!

[Manky Monkey]

More! We want more! 

[merv]

More! We want more!

Don't let your public down

[Manky Monkey]

Chris, have you got any snaps of your much admired aluminium "Airstream" trailer?

[phunkie hiboy]

Chris, have you got any snaps of your much admired aluminium "Airstream" trailer?

I've got some, yes. Just to keep some interest up on something different, I probably got enough to do a build thread. I didn't take that many to startwith, but as things needed to be overcome i took more photos. I'll see what I can put together.   

[phunkie hiboy]

Whens the next instalment?

Now ....................

So with the right hand side riveted on, it’s now time to turn attention to front and rear walls and the upper door.
The upper door did require some considerable repair work. All the “damage” probably happened, either when it was pulled from its mould or when the inner and outer skins were clamped and laminated together. All the cracks were ground out to below the gelcoat and filled with resin and chopped strand mat. This was then sanded and filled with normal body filler to get a smooth finish.

Phunkie Project Portafold (caravan!!)

The ends really didn’t need too much attention, so together with the upper door were sanded and primed. A quick guide coat and left overnight. The following day all the panels were sanded and sprayed with three coats of “Old English White”.

Phunkie Project Portafold (caravan!!)

Phunkie Project Portafold (caravan!!)

Phunkie Project Portafold (caravan!!)

Once the paint was dry, the hinges were added to the ends. The following day the flat seals were added to the main body, at the ends, and the ends then fixed to the main body using stainless steel screws (they don’t rust like the old ones!!).

Phunkie Project Portafold (caravan!!)

Phunkie Project Portafold (caravan!!)

Phunkie Project Portafold (caravan!!)

So now onto the major problem of it all, the roof. This was pretty bad and even with the work carried out on it so far, it’s far from perfect. What has got to be remembered the more strength we add the more weight we add, therefore making it more difficult to lift.
All the starring has been ground back to below the gelcoat and more so on the structural repair area on the right side (where obviously the  wind had caught the roof at some point and split that side and damaged the centre strip of the roof). The normal repair to all these areas was carried out (resin and chapped strand mat).This will be allowed to harden off before sanding and filling.

Phunkie Project Portafold (caravan!!)

Will get round to a bit more this weekend …………

[Bus Boy]

wow!!!!!!!

[phunkie hiboy]

Sorry it’s been a while since I updated this thread, but we’ve been really busy. So anyway here’s the next short instalment ………………………..

Now the roof has been repaired (ish, really it needs replacing) it has been sanded down and all the repairs filled.

Phunkie Project Portafold (caravan!!)

After which it was sanded down again and sprayed with epoxy primer and 2 pack hi build primer and sanded down again for the colour coats.

Phunkie Project Portafold (caravan!!)

The colour coats were added and then 3 coats of clear lacquer. We decided on another period colour, Rootes “Electric Blue”, that was very popular back then, to paint the roof.

Phunkie Project Portafold (caravan!!)

Phunkie Project Portafold (caravan!!)

Whilst the paint was drying, I cleaned up all the windows and refitted them to the walls.
After the paint had dried the fixings were riveted back on and the roof placed on top of the rest of the assembly.
To hold down the roof we have had made a couple of leather straps, which have to be shaped and treated before they can be fitted.

Phunkie Project Portafold (caravan!!)

These will be shaped (into a flat circle) and then treated with dubbin to protect them from the weather.
Managed to get the Portafold back to home yesterday (Saturday) afternoon to start fitting the interior out over the extended weekend. We’ve less than a week before we need to tow it down to the New Forest (Pylewell Park) for its first event!!

[Manky Monkey]

Doing a crackin' job there Chris. Love the colour.

[digger06]

nice, i had one years ago, used to pull it with my camouflaged cabriolet 2cv,  

my mates used to recon it looked like a mobile tea stall!!!
it slept 2 v easy, had a sink and a kitchen of sorts in it under the beds ,

wish i still had it