Revcon Rebuild Part 12: Interior Walls

When we purchased the Revcon, we were provided with bamboo for the inner walls. We had intentions of using it and even outfitted the back wall and upper walls of the cab with it. Then the upper cab windows leaked. The bamboo wrinkled like a wood-like product would. When we purchased the Revcon, it was floor to ceiling in mold. We decided to abandon the bamboo. (Yes, the upper windows will be repaired)

We opted to use ABS for the inner walls. We decided on a textured white. It is a huge departure from our original plan but it is waterproof, mold proof and easy to maintain. It is rigid yet flexible so works with the curvature of the walls. And it is easy to cut. To balance out the white, we're planning on wood cabinetry.  

 

 

 

We still have to do the rear wall and upper cab walls. But those will wait. We needed to get the Revcon dried in so we could transition to other awaiting projects. Sadly, this giant will again go to the back burner. I have stopped setting timelines with this project because plans consistently change and other projects need attention before spring/summer.  

We're pleased with the how it turned out. The light tan exterior looks great, the white walls really make the space feel open and bright. Having new lighting and fresh paint really makes the Revcon look new.

Revcon Rebuild Part 11: When a Week Turns into a Month

We took a week off work in early November, specifically to finish painting the exterior of the Revcon. We got all 5 RV windows removed at dusk, only to realize that southern Arizona would see the first measurable amount of rain in over 100 days. I had checked the weather several times the week prior and wasn't expecting this storm. It rained all night and into the next day. Humidity was sky high and it was cool out. Three days into our vacation, it cleared up enough in the afternoon and we taped off the cab to prep it for primer. Mike primed the cab clear into dusk.  

 

We laid primer on the driver's side RV the following afternoon, followed by color on the cab that evening. The following afternoon, Mike applied color on the driver's side RV.

 

By this point, we were back to work, so got as much prep work and paint done in the evenings. Which are pretty short this time of year. So in true fashion, we got primer and color on the passenger's side...in the dark.

 

Now into December, we were able to get all the gaping holes plugged up. The Ford got brand new headlights. After our trek back from Portland with only one functional headlight, it was well worth the money. New tail lights, marker lights and a back up camera were also installed. All the trim got a fresh coat of black and the RV windows/frames were sanded and painted black as well. 

 

 

Finally after installing interior walls (I'll go into that in a follow-up post) all 5 windows were installed. And it looks like progress was made.  

 

Revcon Rebuild Part 10: Year Long Hiatus

It has been a full year since we made any progress on the Revcon. Mike returned last Thanksgiving from a 3 month work assignment. We then dove head first into two truck builds that wrapped up this summer and fall respectively. It felt like the right time to make any progress on the exterior of the Revcon.




Arizona had been unseasonably warm and dry. We took time off work, specifically to finish the exterior paint this past week. So we popped out the 5 remaining windows and did some finish sanding. Only to find out that the following day, southern Arizona would see the first measurable rain in 110 days. Of course.

 

So we taped the five gaping holes and ran errands during our rain delay. In between fits of wind, we managed to tape up and prime the cab. Desert winters just don't have enough daylight.

 

In the meantime I got to work sanding/painting the windows for the driver's side RV section.

We lost so much of this week to rain, humidity and wind. We blindly moved the Revcon to the rear of the shop yesterday to put primer on the driver's side RV and paint on the cab. It is an interesting experience driving a 31' RV blindly, with just the guidance of your spouse, be we did it.

I'm bummed we're, yet again, behind on progress but we still hope to have it dried in as soon as possible. If the afternoon desert winds will cut a break sometime this week, we may just get the driver's side completely done. Hopefully by Christmas (fingers crossed), both sides will be done. Just maybe.

 

We will both be happy to put this part of the renovation behind us. Once the walls go up, windows installed, we can plan out the interior build while we tackle a few projects in between. Sadly, this sandy beast just gets the short end of the stick when it comes to our attention, but a personal project and a paid project are creeping in after the New Year.

Revcon Rebuild Part 9: Window install

It's weird how excited I am that the three windows we took out in May are finally back in.  All three bamboo walls came out beautifully, which meant the windows could go back in.  The two front windows went in with little effort.

The rear window, on the other hand, fought us tooth and nail.  For some reason, it seemed like the fiberglass shrank.  We just couldn't get the window to fit.  But in the end, with a lot of effort, it too was in, which meant we are finally dried in.

And shiny new tail lights. 

We still have both sides of the Revcon to repaint.  But reaching this milestone feels pretty good.  We know what to expect now with the two aluminum sides, and they'll be done independently of one another so only one side is exposed at a time.  We're getting there. Slowly. 

Revcon Rebuild Part 8: Flooring and Walls

The heat is starting to take it's toll.  It hasn't been below 105* in over a week.  It has been pushing 110* quite a lot which limits our time on the Revcon.  

The more we work on it the more of a puzzle it is.  Can't reinstall the windows without interior walls.  Can't install interior walls before replacing the rotted floor because some (not all) of the insulation sits directly on top of the floor.  

So we ripped up the floor.  But a funny thing happens to steel screws when their imbedded in aluminum and become rusted.  They don't turn.  Mike had to rip the ¾" plywood by brute force alone.  Then we could grind the screws out.

Once removed and cleaned, we were able to insulate the floors.  

Then we could start, in earnest, on the walls.  Mike made patterns, then cut out the front cap walls out of birch.  We were hoping that the birch would look good enough to clear coat and be finished walls, but the ply is too fragile and it just didn't look finished.  So we made the decision to move forward with laminating bamboo to them.  

This is the first time we're trying this laminating thing out.  It was tedious, but I got both walls cut, fitted-ish, and glued.  I have no idea what they look like since it has been 110 everyday this week when we get home from work.  I really hope it works out.

While I was doing this, Mike was working on the floor panel for the rear of the Revcon.  The back wall couldn't be fitted without the panel in.  Once fitted, we covered it with sealer and set it in place.

We're hoping to get as much progress done as possible before our camping trip.  Two weeks from now we'll be in cooler temperatures in the quiet northern desert living out of our teardrop and Jeep.  

Revcon Rebuilt Part 7: Painting the Rear Cap

It has been a hot minute (literally) since I've updated.  Summer is in full blast here in southern AZ, so we're only fitting a few hours of work in the evenings.  Usually, it is at sunset or early morning.

But we've been plodding along with the rear of the Revcon.  We concentrated on the fiberglass sections first, before moving onto the aluminum sides.  The rear cap needed additional rivets, holes filled with fiberglass, and of course loads of sanding, prep, primer and paint.

It was over 100 by 8:00AM yesterday when Mike finished.  Too hot to actually paint, but he finished off the rear cap and roof.  While he was painting, I scraped, sanded and painted the rear window so when it is time to install, they are a crisp black, as opposed to scratched and faded.

Summer slows us down tremendously.  But we're trying to get her dried in before monsoons arrive.

Revcon Rebuild: Part 6

I'd love to say that the cap is completed.  But it is not. Yet.

Body work is hell.  Sand down old, textured paint.  Remove loads of sealer and adhesive.  Primer.  Sand again.  Epoxy paint.  Sand again.  Paint. 

But it has color.  We stayed tan, just went a different shade.  It is actually off of a 2009 Toyota FJ. 

So the cap has color and about 60% of the roof.  The new Maxx Fan has been installed, as well as the new front marker lights.  

We were attempting to install the windows in the cap when we realized that the way they're made means that the interior walls need to be installed in order to get a solid seal.  Well that isn't practical right now.  75% of the Revcon still needs to be sanded and painted.  Which means huge windows will be out for a significant amount of time.  With monsoon season starting on the 13th, we can't risk putting walls up now.  So...at some point soon, it will be entirely windowless.  For the shortest amount of time possible, but still. 

Revcon Rebuild: Part 5

Sometimes no matter how fast you run, you still feel like you're standing still.  We're in that place with progress.  We're constantly working, but it is hard to see the fruit of our labors right now.

We're prepping really hard for paint. And it is tedious work.

If you need me, I'll be on the roof.  I live here now.  I've spent most of my time removing sealer, adhesive and sanding.  Then removing more sealer.  And then more of it. 

Meanwhile, Mike has been working hard on finishing up the fiberglass work.  The front cap required more layers.  We tag teamed it last night and added five more layers.  Then today, he finished it with epoxy body filler.  Additional holes on the rear of the Revcon also needed to be filled today but weren't ready for filler today. 

Once the cap is sanded, it should be ready for primer and paint.  Mike removed all the old sealer, filler and whatnot from around the truck and cabin, so we're inching closer to starting paint on at least part of this behemoth.

Revcon Rebuild: Part 4

How is it Friday already?  Part of me is pleased with all we accomplished this week, and part of me wonders what we actually did.

Wednesday (I think) I sanded the excess fiberglass insulation off of the panels.  

Mike wanted to spray Lizard Skin on the walls before we insulated.  It is typically used in car builds to keep heat and sound down.

It was pretty noxious, so I didn't hang outside.  He was out til about 10PM, knocking it out.

This is the final product:

It was our first time using it, and we actually noticed a difference.  Under direct sun, the aluminum roof panels were fairly hot to the touch.  Not so much anymore.  

Not surprisingly, we noticed the adhesive they used to marry the skin to the studs had solidified and began to fail.  Mike scraped it all out, I drilled holes for new rivets, and he backfilled with new adhesive before riveting the body to the walls.

While he was riveting and messing with wiring, I spent the better part of two days installing foam insulation panels.

All of the cavities that can be filled, are.  We can't tackle the bottom until we rip up the rotten subfloor and replace it.  But with 75% of the camper done, it is noticeably more temperate inside than it was.  

One thing that happened today was unexpected: a microburst.

Right as we were getting started to work, a microburst blew through and took our awning off the side of the Revcon and twisted it.  We were able to get it upright again, but mechanisms are bent beyond repair and it will have to be replaced at some point.  A huge hit to the budget.  Much cursing and sweating was done to try and save it, but we don't think it is serviceable beyond acting as shade while we work.

Such is life with B.O.A.T. (Bring Over Another Thousand)