Mr Tin Can Plan

Building Airstream cabinets for your vintage trailer restoration can be a bit daunting. Woodworking is a skill that people learn over many years. I don’t particularly have great skill when it comes to woodworking. My method usually consists of measuring, cutting, then immediately throwing that piece of wood away, re-measuring and cutting again! Sometimes, I like to repeat this process 3 or 4 times. Woodworking is tough stuff!

2012 International Cabinets

Cabinets in new Airstreams

In newer Airstreams, you’ll often find something that is considered lightweight MDF. From my experience owning a newer Airstream, it seemed that the cabinets were similar to IKEA in build and were laminated like IKEA cabinets as well. I’m not saying this is a bad thing, just an observation. Heck, I like a lot of stuff from Ikea myself. I’ve even modified their cabinets to fit in a vintage Airstream.

Cabinets in old Airstream

Unrestored 1966 Airstream Globetrotter Interior

The cabinetry in older Airstreams was a bit more lightweight than today’s trailers. They were made with very thin plywood and typically fit into small aluminum channels and were nailed together. When you start a vintage trailer project, I suggest you be very careful when removing these parts because you may want to reuse them or at least use them for templates. You might even keep them and sell them to another person to use in their project if you’re changing everything.

Building the cabinets in a vintage Airstream

In this project, the layout was completely changing. Which meant I was starting with a clean slate and wouldn’t be using any of the old wood or cabinets. Plus, the wood itself had become very smelly!

Dresser and oven cabinet in progress

Years of rot had taken its toll. Once the trailer was empty, I started building the cabinets. For this trailer, we knew we wanted a dresser of some kind, a wardrobe closet, a bathroom cabinet, the kitchen and finally, the front dinette area.

Dresser Mrs. TCP built

Kitchen Cabinet “Base”

Materials to build Airstream cabinets

I decided to make all of these with ½ inch sanded plywood. It isn’t the best wood for cabinets, but it is mostly lightweight and is easy to work with. Make sure you use new blades or you’ll tear up the edges.

Kitchen Cabinet “Face”

For most of the cabinets, I used the ½ inch plywood for the “face” of the cabinets and ¼ inch plywood for the “walls.” This meant that the cabinets would have a front that could be easily removed in the event of a water leak, or to work on anything that is behind the cabinets. These include the furnace, the electric panel and more.

Unpainted Airstream Cabinets

Bathroom Cabinet

Once the cabinets were in, we decided to paint them. Once they were painted, I realized I didn’t like them painted! But, that was that. I wasn’t about to sand them all back down and stain them.

Painting Airstream cabinets

I should have stained them in the first place. For now, I can live with the cabinets the way they are. The biggest gripe I have is that we painted the cabinets black so dust and dirt shows up really well, both in person and in a photo.

Airstream Pantry above fridge

So far, I’ve traveled with the trailer on the road and all of my cabinets seem to be holding steady. No cracks or breakage yet. I hope they stay put for a long, long time.

Airstream Panoramic Windows

When you buy a newer Airstream, I’m betting the gorgeous front panoramic windows in the front of the trailer is a major factor in your decision. The view from the inside looking out is one you won’t soon forget. You’ll pull your Airstream up to the campground, face it out towards the world, grab a PopTart or beer and take in the view.

These windows are what set Airstream apart from a lot of other trailers.  Some Airstreams even have these windows on the front and back! This is just one of many reasons I love Airstreams so much. But, those windows come at a price… If one breaks, the replacements are expensive. Not only that, it is a lot of work to drill the old frames out and replace the glass. 

Building the Airstream Window Protectors

Did you know Airstream used to put these same panoramic windows on the Argosy trailers of the 70s? The big difference is that back then, they didn’t come with the protectors you see on today’s Airstreams. At least as far as I can tell by the brochure. These “sunglasses,” as I like to call them, keep rocks and road noise from smacking into the glass and shattering it. Now, I’d love to purchase the sunglasses, but they cost a fortune. One day, I might swing for the official protectors but for now, I’ll make my own.

DIY Airstream Rock Guards

There are many ways you can protect your panoramic Airstream windows. There’s canvas material you can make and “snap” onto the trailer. You can even go the old duct taped cardboard route. We did when we first brought the trailer home. Many people end up making them out of Plexiglass or something similar. I chose the Plexiglass method.

First, I had to figure out a way to mount the Plexiglass to the trailer. I thought I might use some sort of metal or just screw it in directly. I even thought about making the frame out of aluminum channel. There’s a lot to consider when building something as unique as this curved window protector.

I chose to use some plastic conduit I found on the electrical aisle of my local hardware store. I even found some rounded elbows that would work for the curved section. Cutting and bending the plastic tubing was easy. I then screwed the tubing into the trailer. If you ever drill holes in your Airstream, I suggest you dab some polyurethane caulk in there with the screw. A few drops of water through a screw hole over a long period of time will certainly rot your floor. Water has a way of finding its way into Airstreams and goes right down to the floor.

Next, I cut the Plexiglass. This part isn’t easy! This stuff cracks easily so you have to be very careful when sawing or scoring the sheets. I used the real thin stuff because I didn’t want to spend a lot if it wasn’t going to look good once installed.

Remember to think about the horizontal curve and the upward inward curve of the Airstream window and body. I made a few mistakes on the first piece of Plexiglass, which was an expensive mistake. On the second part, I knew exactly how to cut it and make it fit. Even then, I still cracked it in a few places. When cutting Plexiglass, it is best to tape the edge you plan to cut to keep it from cracking.  It is a lot harder than it seems. I used a jig saw blade that is made for Plexiglass when cutting the curved part of the protector. 

I used rubber washers when screwing the “glass” into my conduit framework. I didn’t build a protector for the middle glass windows. I’m hoping the middle is less susceptible to breakage. And, if it does, it isn’t as devastating as the fishbowl piece. We’ll see how well the protectors hold up on the curved ones when flying down the highway.

If your Airstream or vintage trailer has been sitting in the same spot for a long time, it is likely due for an axle upgrade. Replacing them with new axles is not necessarily an easy task, but it can be done. It really depends on your skills and the tools you have.  Many people would say you don’t really need to replace them and some will say it is absolutely necessary. I say it depends on the trailer. In this particular case, the answer was clear.

Height of wheels in wheel well before axle replacement

Airstream tires removed and axles awaiting removal

Airstream Axle Replacement Cost

There are a lot of factors to consider when replacing the axles on a vintage Airstream. Are you going to do the work yourself? What part of the USA or world are you in? How much do you want to spend…. First, I’m a DIYer to the max, so of course I replaced the axles myself.  But, there are a few tools you need so you need to factor that into the cost. Plus, the axles are HEAVY! Shipping costs are expensive. I was able to pick mine up in Arlington, Texas.

I ordered the axles from Inland RV out of California. It seems there are a lot of middlemen between them and the customer. For instance, you order from Inland RV, who I suppose then orders from Dexter (the axle maker) who then ships them to Redneck Trailer Supply in Texas. I reckon you might be able to order them direct. You also have to get someone to weld on the shock brackets.

Airstream Axle Installation

In the simplest terms, in order to replace axles on an Airstream, you just unbolt the old ones and then bolt on the new ones. This is the case if you get the axles from Inland RV. I’m not sure if there is another way if you order them elsewhere.  During the installation, you’ll find that one hard part is getting the old bolts off the trailer. They are usually seized by rust and you may have to cut them off. The actual HARDEST part in my opinion is getting these heavy suckers under the trailer. Each one weighs about 250 pounds or so. Seriously, between the task of getting the axles in and out of the truck, then dragging them to the trailer, then “sliding” them under the trailer, then using all of your strength to get them in place, you might just give yourself a backache, a hernia or busted finger. OR, ALL OF THOSE. Maybe it is best if you have some sort of dolly system and concrete to work on and not dirt and grass and good ol’ fashioned HeManism to get the job done. ..

Once the axles are on, you will see that you get quite a lift. The axles also come with  shocks which you mount at the same time. In this case I added the Dexter lift kit to give the trailer even more of a lift. I did this to ensure my new tanks don’t drag on any dirt roads I’ll soon find myself driving down.

If you plan to install new axles on your Airstream, remember that you are going to spend a lot of time on your back and UNDER the trailer. Make sure you have some sturdy jacks. The trailer falling on you is a very real concern. This is hazardous work people!

Once the axles were on, I discovered that my old vintage wheels wouldn’t fit on the hubs! Of course, this was after I had already purchased tires and had them mounted. I then had to go back to the tire shop and claim to not understand why they wouldn’t fit…. I paid for the tires to be mounted on my newly purchased wheels and installed them on the Argosy.

With the lift kit, the new shocks and the new tires, the trailer is MUCH taller than it was before. I just might have to add an extra step to get in the door!

MR. TCP

Painting an Airstream Is No Joke!

Technically, this is an Argosy, not an Airstream. The difference between an Airstream and an Argosy is the Argosy is painted and Airstreams are usually shined. Also, when the Argosy was available from Airstream, it was considered a “budget” trailer. It was dubbed “The Mid-Priced Travel Trailer with the Airstream Pedigree!” Classic.

Sanding and Stripping Paint from an Airstream

Over time, paint fades, chips, cracks and gets scratched. Especially, if it sits in the sun for an extended period and never moves, or gets washed, waxed or even looked at. On something as large as a vintage travel trailer, this becomes obvious. I started with a paint stripper product from The Home Depot. It worked, but it was real slow and time consuming. I like to GET THINGS DONE.

With the stripper, all it really took was slapping it on the trailer and then 2 minutes later, scraping away the paint. But, it would leave some paint and residue on the trailer that was hard to get off. So, out came the power sander! I’ve read you shouldn’t do this, because it will leave nasty scratches and swirl marks. That did happen, but I went back over it with a finer grain of sandpaper and knocked the scratches down smoother. Mrs. Tin Can Plan even got involved and did some of the sanding! I thought that once I painted it with primer, these lines would fill in and you wouldn’t see them. Guess what? I was right.

Painting an Airstream with primer

Next, I bought some Self-Etching Primer from Rustoleum spray paint. I had to purchase a TON of cans in order to get the whole trailer painted. Where we are right now, every other day it was either really windy, cold or raining, so it took quite a bit of time to finally finish priming the whole trailer.

The primer creates a nice, rough finish for the final top coat to cling to. When I first started priming, the color is almost green. To anyone watching (my neighbors) it looked as if I was painting this ugly trailer a nice shade of CAMO! I found it very amusing at the time. It dried a flat gray color.

Painting an Airstream with a roller

Finally, I decided that since the wind would never stop blowing, that I would just use a roller to for the final paint job. I read a few blogs and posts about what kind of paint people use for cars, boats and other things. They use very expensive, hard to find paint. I wasn’t interested in that expensive stuff, because, frankly, I’m painting the sucker with a roller! Who does that?!

Exterior Argosy and Airstream Paint

I used the oil based metal paint you can find at The Home Depot and went to town. I thinned the paint and then rolled on a first coat. I used foam rollers so there wouldn’t be any fuzz left in the paint. Next, I wet sanded it, then I painted again. Then, I wet sanded with a finer grit. Then, I painted again! I did this about 3 times. For an exact step by step, check out the blog at Argosy Traveling as they have a great step by step on how to paint an Airstream as well. The trailer is now GLOSS WHITE and I did end up with some dirt, grit and bugs stuck in the trailer in some places. But, that’s what happens when you paint outside. 

The final paint job does have some “orange peel” in it, but I can live with it. You can’t see it until you get close to it. That’s a running theme with my work. Stay far back! Since I used a paint you can find just about anywhere, I’ll be able to do touch ups when the paint scratches off. 

What’s the best part about painting an Airstream? Not having to polish it!

Mr. TCP

Restoring an old travel trailer or Airstream to its former glory is a tough job. But, the end result can be truly amazing. You can find yourself in a fully customized and modern tiny living space that is as unique as you are. And, with a little DIY elbow grease, you can save big!

Let’s just get back to the tough part for now. We know from experience that a newer trailer, in our case an Airstream, is just about the easiest way to go camping or roadtripping. Most days, the hardest part will be hitching it up and then parking. Once you’re in, you’re in. With a few switches flipped and a few valves turned, you’re all set. You’re down at the lake before your Atwood has even hit 80 degrees.

That may not be the case when it comes to an old trailer or Airstream. Back in the day, everything, and I mean EVERYTHING, was manual. On some trailers made today, that is still the case. You light this, you light that. The fridge, the water heater, the furnace, the stove, etc. Then, some days you find things just don’t light. And, some things just don’t go right!

We all know modern trailers can be expensive. Especially, Airstreams. If you’re looking for a chance to own one, and have a few skills, or at least determination, you can find yourself in a nice, newer, Airstream for less! That’s the plan anyhow.

Which brings us to the lovely 1977 Airstream Argosy.

This is a bit of a different Airstream. If you’re unfamiliar with them, they were manufactured for a short time and were known as the painted Airstreams. They were also the name of their motorized line of coaches or RVs.

We picked up this gem in Arkansas and towed her back to Texas. The Argosy came with all the original paperwork, which is rare! According to the documents, she was made in Ohio and someone in Tennessee owned it first.

I’ll consider us lucky because we made it back to Texas without any problems. The next day however, I took a good look at the tires and thanked my lucky stars. These must be the original tires or darn close to it! We even lost a few lug bolts on the way home…. Then, we really took in the project. WOW.

The trailer is a wreck now, but in no time at all, we’ll have it modernized and ready to hit the road. The toughest part is just upon us.

–
Mr. Tin Can Plan