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Subject Topic: esterel underside help Post Reply Post New Topic
Personmr-mac
27/5/2012 at 11:45am
 Location: Tayport FIFE
 Outfit: Esterel View mr-mac's Profile View Profile   Reply to mr-mac Reply   Quote mr-mac Quote  
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Hope someone can help with advice and see if any of my thought on sorting the underside of new van will work... if not I think I an knackered.
Wasn't sure if to post here or in folding caravan forum so here is link to other post to keep any help\ discussion in one place


link

Thanks

John


PersonAl+Mel
27/5/2012 at 8:41pm
 Location: Hants
 Outfit: Fleetwood Heritage 640 EB & ML270 View Al+Mel's Profile View Profile   Reply to Al+Mel Reply   Quote Al+Mel Quote  
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I think you are on the right lines with your West Epoxy ideas. Some photos would be useful, but in the interim, could you create sub frames by cutting back to the good ply, then undercutting the foam so you can insert a frame that can then be epoxied (and screwed whilst setting) to the old ply and the new stuff?

Thinking along boat repair lines, if you have to use screws into the framework, can you drill oversize holes, flood these with epoxy/microballoon paste then drill pilot holes into this for fittings? That way it will keep the framework dry, as your screws go into epoxy, not wood.    


Personmr-mac
28/5/2012 at 6:54am
 Location: Tayport FIFE
 Outfit: Esterel View mr-mac's Profile View Profile   Reply to mr-mac Reply   Quote mr-mac Quote  
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Nice one thanks, seen another post where someone had similar issues and found floor was too far gone for normal delamintion repairs so they added some 16mm marine ply after doing normal repair and then drilled and screwed through dowels from above to screw down into new marine ply on underside which was also glued.

I think I am going to do the same but other way round. Basically hammerite the sides of metal subframe to protect them more some marine ply from edge of van to metal subframe use epoxy\or glue and jack it in place and allow to set (maybe install a few dowels from top side to screw through to new ply without compressing floor - little west along edges where it touches metal subframe to ensure no water can get in and damgge new ly or metal and any gaps where it meats edge of van) then new ply on underside will provide strength and seal underside from water getting in. Once that's done I then treat from above with normal delamination holes, epoxy then dowel type treatment which will stick delaminated ply to foam better, add strength and soak into any damaged ply or fill any missing bits between new ply and foam (once set I may then drill and countersink a few more dowels and screw to new lower floor).

I am in two minds whether to take out any ply from underside that is brittle enough to take off by hand (I will ensure it's all dry with no damp before new ply added. My quandary is if it's that brittle the epoxy from above should soak into it easily and give it the strength back. But which would be better epoxy soaked damaged ply sandwiched between new and foam or a gap filled purely with epoxy????

Will just do a bit at a time until rear and edges are done then find something to treat whole underside.

Corners and sides look ok and floor from above doesn't feel bad to walk on (and I am 16 stone so guess top ply is quite strong and most of floor is solid). A tiny bit of damp on outside at wheel arch where floor is dodgy so will ensure it's sealed when I tackle floor to stop it getting worse then tackle that later if it needs it.

Just got very little money and that marine ply and epoxy delamintion kits etc. aint cheap.

Once that's done roof looks to have sagged a little at one side thing the lining panel has just come unstuck and was giving it strength so plan to epoxy it back to roof then use a strip of wood and some posts to hold it back in shape while epoxy dries.

It may not be perfect but think it will at least keep the van useful for a long time.

Got to get it set up and find out how the 12v system works (willing to bet just a transformer off 240v and no leisure battery system). Sort curtains...

Least if I can get it strong, safe and sealed on underside and roof back to good shape (though it's not too urgent and not to bad) I would not worry about selling it (in current condition I would feel wrong taking money for it).

As it's an older esterel the classic car community would be interested and if I am lucky I can maybe get enough money to get a slightly newer one :) As that may work out better long run than making this one perfect.

Anyway if I can get the repairs done over next 3-4 months (may just get a bit of ply at a time then epoxy etc. and just do whole job at same time) the van should at least last me this year and next by which time I will know if we use it enough and if it's working out for us and maybe, just maybe save a little extra to upgrade this van or upgrade to nicer folding. Maybe if I keep my eye on gumtree I could find a free esterel in Scotland (you know a dead one that isn't being repaired) and get the lighter furniture and cooker unit that has cooker with grill and maybe fridge that will also run on gas).

Anyway first break planned for start of June so getting a few things like plates, bedding etc. and gonna set van up and check out electrics (240v has new wiring and circuit breaker) but want to see how 12v works (if at all) and check drainage and freshwater connections.

Thanks for advice.


Personflirtymyrtle
04/6/2012 at 9:09pm
 Location: Hampshire
 Outfit: Esterel 42T Folding Caravan View flirtymyrtle's Profile View Profile   Reply to flirtymyrtle Reply   Quote flirtymyrtle Quote  
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Hi, I've recently started renovating my Esterel 42T which sounds very much like yours except the door is on the French drivers' side.

LINK

I am on a VERY tight budget and couldn't affored marine ply so my aim was to at least get another couple of years out of her before I replace the ply again. Your repairs sound like they're going to be more 'professional' than mine were!



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