Green Boler Rebuild 2

Having help with the trailer made the project a lot more fun!  and the project started to take off.

We cared the trailer outside, and spent a few days finishing up the sanding.

boler sanded

With the windows in the trailer either broken or no able to open the new windows I ordered from Sunview industries arrived.

new boler windows

 

I also picked up the insulation for the inside.

Insulation purchased for the BolerNow it is time to attack the fiberglass repair, with help that is comfortable tackling this.

Boler Waiting When I Arrived

Boler Waiting When I Arrived

We used some really thin wood, screwed onto the outside as a form, covering them with wax paper to ensure it would break free.

First hole to cover for fibreglass

First hole to cover for fibreglass

Acetone and paper towels to clean everything up

Acetone and paper towels to clean everything up

Finished form from the inside

Finished form from the inside

Back hole ready, time for the next one.

Back hole ready, time for the next one.

12 05 P5 Boler Hole formed

Sanded and cleaned with Acetone

Sanded and cleaned with Acetone

Covered the holes with wax paper and used tape to make the edges so I would know where to put the wood.

Covered the holes with wax paper and used tape to make the edges so I would know where to put the wood.

 

Inside once done and ready for fibreglass

Inside once done and ready for fibreglass

 

12 05 P1 Boler Project

Cleaning the fiberglass cut out (the Boler was previously modified as coffee cart)

Cleaning the fiberglass cut out (the Boler was previously modified as coffee cart)

The outside of the hatch was covered in paint, calking and rivets.

The outside of the hatch was covered in paint, calking and rivets.

The floor under the front bench has been broken, so we screwed wood down to make a form for the fibreglass.

The floor under the front bench has been broken, so we screwed wood down to make a form for the fibreglass.

A picture of the front floor formed up from the outside and ready to be fibreglassed.

A picture of the front floor formed up from the outside and ready to be fibreglassed.

Using body filler for the first coat.  Wax paper was used to keep it from sticking to the wood form.

Using body filler for the first coat. Wax paper was used to keep it from sticking to the wood form.

Then we applied the fibre cloth and brushed on the resin.

Then we applied the fibre cloth and brushed on the resin.

The door had been damaged and then painted.  So I took the grinder and cleaned it up, the using a thin flexible piece of wood, screwed it on to take the shape of the door.

The door had been damaged and then painted. So I took the grinder and cleaned it up, the using a thin flexible piece of wood, screwed it on to take the shape of the door.

Put a layer of body filler on the door as well, will trim it up once it dries.

Put a layer of body filler on the door as well, will trim it up once it dries.

Putting Body filler on the other cut out on the trailer as well.

Putting Body filler on the other cut out on the trailer as well.

Applying more cloth and resin to the other forms, before running out of supplies.  With the store closed for the night we called it a day.

Applying more cloth and resin to the other forms, before running out of supplies. With the store closed for the night we called it a day.

Pulling off the wood we discovered the body filler did not harden.  It needed to be left open to the air, not sealed between the fiberglass and form.  Luckily the fiberglass took the shape, so it should be easy to make this right.

Pulling off the wood we discovered the body filler did not harden. It needed to be left open to the air, not sealed between the fiberglass and form. Luckily the fiberglass took the shape, so it should be easy to make this right.

Paul marking out the window openings

Paul marking out the window openings

The help turned out to be huge, it wasn’t that he was good with fibreglass, or anything else we were doing, he had a much more valuable skill, he just attacked the problem and figured it out, regardless if he knew how.  With this a few things could have been done a little better, but the jump in and figure it out approach was so effective I adopted it for the rest of the project.  An amazing lesson and gift to this project.

Next we cut out the openings for the windows.

Paul marking out the window openings

Paul marking out the window openings

The cutting begins

The cutting begins

The old cut out was not straight and the corners not round, we will need to fill one corner, other than that they fit great.

The old cut out was not straight and the corners not round, we will need to fill one corner, other than that they fit great.

Here I am holding the new window in to see how it fits.

Here I am holding the new window in to see how it fits.

Hatched screwed in waiting for fiberglass as seen from the inside of the Boler.

Hatched screwed in waiting for fiberglass as seen from the inside of the Boler.

Window frame in and hatch screwed into place

Window frame in and hatch screwed into place

Floor repair took well.

Floor repair took well.

Floor repair as seen from the inside.  A little touch up and it will be great.

Floor repair as seen from the inside. A little touch up and it will be great.

Lifting the boler up onto saw horses it was time to undercoat it.

Boler shell and frame freshly undercoated

Boler shell and frame freshly undercoated

Freshly under-coated, the cleanest the bottom will likely ever be.

Freshly under-coated, the cleanest the bottom will likely ever be.

The front floor was damaged.  Now with new fiberglass and undercoat it is strong again.

The front floor was damaged. Now with new fiberglass and undercoat it is strong again.

The big cut out in the back, and smaller holes on the side have all been fibreglass.

The big cut out in the back, and smaller holes on the side have all been fibreglass.

This was the part I was a little worried about.  Now the panel is fiberglassed in and  looking good.

This was the part I was a little worried about. Now the panel is fiberglassed in and looking good.

Picture of the repair from the outside

Picture of the repair from the outside

Somewhere while doing the fiberglass work, an unexpected change to move to Edmonton was made, and with short notice I had to sell my business, sell the house and get the trailer ready to tow to our new home.

Frame getting twisted back into the right shape and reinforced.

12 05 P1 Fixing the frame bend

With the frame repaired, I also painted it while the shell was off.

With the roller out I decided to paint the frame as well

With the roller out I decided to paint the frame as well

Boler is now undercoated.  With a few random screws pulled out of the bottom this should seal up anything I missed.

Boler is now undercoated. With a few random screws pulled out of the bottom this should seal up anything I missed.

The hatch that was cut out by a previous owner is now fiberglassed back in.  I am surprised at how well everything ended up lining up.

The hatch that was cut out by a previous owner is now fiberglassed back in. I am surprised at how well everything ended up lining up.

The hatch patch from the outside.

The hatch patch from the outside.

The cut out in the back of the Boler is now patched.

The cut out in the back of the Boler is now patched.

The damage to the fiberglass floor at the front of the trailer has been repaired and painted.

The damage to the fiberglass floor at the front of the trailer has been repaired and painted.

With the fiberglass repairs done, and the undercoating complete the shell and frame are ready to go back together.

With the fiberglass repairs done, and the undercoating complete the shell and frame are ready to go back together.

Boler is back on it's frame and getting close to being tow-able for our move.

Boler is back on it’s frame and getting close to being tow-able for our move.

Adding new safety chains and wrapping the trailer it was ready for the trip to it’s new home.

12 07 P1 Saftey chains replaced on Boler

Boler wrapped and hooked up.

Boler wrapped and hooked up.

With the trailer in the garage at the new house, the only issue that appeared was the rear patch had cracked a little, good thing it happened now, before paint.

Boler in new garage, crowded by the mess of moving.

Boler in new garage, crowded by the mess of moving.

 

Green Boler Rebuild 3

5 comments


  1. done some major boler fiberglass repair. Might have some thoughts. I know nothing about insulation other than what has been on ” Fiberglass RV.com ” nothing about frame; axle repair with Dexter, by some people.

  2. Awesome…you are the man.supper Dad! The memories you made for your family are priceless.

  3. were did you buy the front and rear windows, I nead both for my 1980 13ft , and accesories, with the tool neaded, but just can not find the imfo I want , I live in mexico , and hopefully they can be sent here , any help would be apretiated , thank you fred plews,

    • The seal for the front and back window was picked up from a auto glass shop, and is used for many windows, so should be easy to source. The window itself is plexiglass, and can be purchased from a glass store or a big box store like home depot. It can be cut with a jig saw to the right size, you just need to go really slow or it will break. You can use the windows you are replacing as a template for the new ones, and to get the thickness.

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