Green Boler Rebuild 3

 

 

Edmonton’s dry climate made working with paint much easier, but the cold winter made many things much more challenging.  Not wanting to wait for warmer weather to get started I took every drop cloth, tarp, towel and piled them on the shell.  Then running an electric heater inside I could make in more bearable to work (still couldn’t get it above 0).

13 P1 Boler covered

 

With this I started installing the insulation.  I used pl400 to glue it up, as it could handle the cold temperatures (I like contact cement better, but it had to warm up to make that an option).

 

The sheet is over the door attempting to hold in the heat, while the door is holding up the insulation while it dries.

The sheet is over the door attempting to hold in the heat, while the door is holding up the insulation while it dries.

A little more still needs to be glued, but it is taking shape.

A little more still needs to be glued, but it is taking shape.

I started leaving the windows cover to keep it warmer, would cut them out later.

With the insulation up I started to work on building the furniture that was missing.  If I could do it again I would make it much liter, but having no idea how to attack this it turned well.  With everything curved, I leveled up the trailer and built everything with a square or level from the floor.

Test fitting the cabinet floor (and the table),

Test fitting the cabinet floor (and the table),

Test fitting the table

Test fitting the table

Sides are on the cabinet

Sides are on the cabinet

13 P5 boler cabinet construction

 

I had seen some other Bolers had extended the counter to the front of the trailer, and liked that option, so I took it a step further and made the bunk the same height as the counter.  This not only gave me a counter extension, but an option for a wrap around counter.  The other piece could have a railing added to make a bunk, or swing down to make a couch.

Counter piece cut and placed in.  It will go to the front of the trailer.

Counter piece cut and placed in. It will go to the front of the trailer.

The bunk / counter piece cut and placed in for fitting.

The bunk / counter piece cut and placed in for fitting.

A shot of the cabinet and bunk progress from the inside of the trailer.

A shot of the cabinet and bunk progress from the inside of the trailer.

Everything was designed with measurements taken from the trailer at the belly band height.  I did not expect the curves to add the challenges they did.

Measurements taken at the  dinette floor height.

Measurements taken at the dinette floor height.

Measurements are approximately the middle of the Boler Trailer.  Curves near to top are estimated.

Measurements are approximately the middle of the Boler Trailer. Curves near to top are estimated.

Top bunk / counter plan

Top bunk / counter plan

Cabinet and Counter Plan

Cabinet and Counter Plan

Kitchen Cabinet and Counter Plan

Kitchen Cabinet and Counter Plan

Plywood plan for this project.

Plywood plan for this project.

I picked up some LED lights for the trailer, a piano hinge for the couch and table, and other hardware for the bunks.

Collecting parts

Collecting parts

I picked up a leg from ikea to support the dinette table.

Table leg from Ikea

Table leg from Ikea

The full sized dinette table seemed like a little too much, so I borrowed the idea of folding it in half as I have seen on other trailers on the internet.

Little E was building an ice cream truck, you can see branches and other random things he’s collected to build it.

Table extension

Table extension

The table support and start of the bike rack.

The table support and start of the bike rack.

The bed is cut, just need to make it into a table

The bed is cut, just need to make it into a table

Storage Covers

Storage Covers

E has been spending lots of time working on the Trailer with me (and you can see the couch cut in the background)

E has been spending lots of time working on the Trailer with me (and you can see the couch cut in the background)

Simple plumbing, it drains into a bucket.

Simple plumbing, it drains into a bucket.

The cut worked!

The cut worked!

The Closet door

The Closet door

Still need to be sanded, and finished.

Still need to be sanded, and finished.

I started on the closet shelves.

Shelves cut to fit.

Shelves cut to fit.

A cut out allows access below the bottom shelf

A cut out allows access below the bottom shelf

Empty Trailer

Empty Trailer

Prepping the Pine for Stain

Prepping the Pine for Stain

Filling the screw holes

Filling the screw holes

Cleaning up the fiberglass furniture.

Cleaning up the fiberglass furniture.

New wood pieces cut for all of the fiberglass furniture.

New wood pieces cut for all of the fiberglass furniture.

With the temperatures warming up, I got out the contact cement and glued the uv stabilized outdoor carpet up.  This should help insulate, keep it dark in the mornings, and hide the seams so there is no need for seam tape.

I did want a wipeable surface on the walls to deal with any spills on the table.  My wife also picked out the flooring, which looked great.

Floor cut and Carpet up!!

Floor cut and Carpet up!!

Starting the Car[et

Starting the Carpet

All the furniture needed to be cleaned, filled and painted.  Any cracks where fiberglassed.  Underneath the paint I found grass, dirt and a wasps nest.

Trimmed up the side (top in picture) of the closet.

Trimmed up the side (top in picture) of the closet.

Adding wood to the fiberglass benches.

Adding wood to the fiberglass benches.

Wood drying after another coat.

Wood drying after another coat.

The door had been damaged at some time, the first attempt to fix it had failed, so I attacked it again, with the ne skills from this project it worked well this time.

After pulling the clamps off.  Inside.

After pulling the clamps off. Inside.

After trimming the door up.  Outside.

After trimming the door up. Outside.

Fixing holes, chips and other damage.

Fixing holes, chips and other damage.

Patching cracks with fiberglass, then finishing with filler.

Patching cracks with fiberglass, then finishing with filler.

I squared off the corners of the benches to make the bed bigger.

Dinette Extension progress

Dinette Extension progress

For the cabinets I found a youtube video, and used this to make the cabinets, bunk rails, mirrored door and it worked great.

Top Bunk Railing

Top Bunk Railing

Doors to hide toilette

Doors to hide toilette

E ran ahead to get ready to paint.

E ran ahead to get ready to paint.

He worked at painting for 3 hours, and was ready to go in at that.

He worked at painting for 3 hours, and was ready to go in at that.

Installed some molding and the front bench to hold the floor in place.

Installed some molding and the front bench to hold the floor in place.

The rest of the furniture goes in.

The rest of the furniture goes in.

I like the wood trim and floor together.

I like the wood trim and floor together.

I also used contact cement to glue on the countertop.

Marking out the counter top to be cut

Marking out the counter top to be cut

Letting the Glue Dry

Letting the Glue Dry

Today's Progress

Today’s Progress

The boys hard at work,

The boys hard at work,

The bottom shelf center lifts out so things can be stored below.

The bottom shelf center lifts out so things can be stored below.

Bottom Shelf of the Closet with insert.

Bottom Shelf of the Closet with insert.

You have to put an Ikea bin in the closet to be a trendy Boler own it seems.

You have to put an Ikea bin in the closet to be a trendy Boler own it seems.

Installed couch back on the hinge.

Installed couch back on the hinge.

Couch flipped up to make a counter top or top bunk.

Couch flipped up to make a counter top or top bunk.

These hold the top bunk up, and easily support someone well over 200 lbs (as I got up there and tested it).

Hardware to support the bunk / counter

Hardware to support the bunk / counter

Hardware to support bunk bed / counter

Hardware to support bunk bed / counter

Glued together the light holder for above the counter.

Glued together the light holder for above the counter.

Assembled table support, so the table can be used as a half table.  This is it extended

Assembled table support, so the table can be used as a half table. This is it extended

Table support closed

Table support closed

13 06 P1 Green Boler Trailer Cabinet Doors

Installed Closet Door

Installed Closet Door

Inside of closet

Inside of closet

Light for above sink and counter.

Light for above sink and counter.

I added a computer fan to the vent, much more affordable that the ones you buy, uses less energy and works great.

Computer fan installed in the roof vent.

Computer fan installed in the roof vent.

Top view

Top view

It was time to finish repairing the outside.  I went through a lot more Bondo than I ever thought I would have.

Bondo and holes cut for propane cooler vents

Bondo and holes cut for propane cooler vents

Windows all taped up

Windows all taped up

Vent holes from the inside.

Vent holes from the inside.

Being cheap I installed a propane cooler.  It was a bad option,  I ended up selling it and getting an old propane fridge that works a 1000 times better.  Got tired of throwing out spoiled food as the cooler would stop working.

Cooler set in to test fit.

Cooler set in to test fit.

New Tongue Jack

New Tongue Jack

LED Light on Wood Mount

LED Light on Wood Mount

White Roof Vent Trim Ring

White Roof Vent Trim Ring

IMG_1077 IMG_1072 adding wood veneer to vent trim ring Boler Trailer

I used old foam sleeping mats for the boys and a $12 air mattress for use to camp the first year.

Boys trying out the beds

Boys trying out the beds

Using a scrap piece of metal I made a bracket to make the bank rail solid and removable.

Starting to make the bunk hardware

Starting to make the bunk hardware

The finished piece, just need paint.

The finished piece, just need paint.

With the squared up corners on the benches, the bed was bigger, and didn’t need an extension that needed to be stored elsewhere.

Table set down to make the bed extension.

Table set down to make the bed extension.

Bed extension Hardware

Bed extension Hardware

Extension pulled out

Extension pulled out

Snack time

Snack time

The parts I used to attach the wires.

The parts I used to attach the wires.

Wires tied up

Wires tied up

LED marker Lights

LED marker Lights

Switches tucked away

Switches tucked away

Adding more moldings

Adding more moldings

I went with a magnetic screen door.  It is great as no hands are needed to open it when loading and unloading the trailer and the boys never leave it open.

Screen door

Screen door

Molding to attach drip cap for the door to and mount the screen door.

Molding to attach drip cap for the door to and mount the screen door.

Added Latches to Cabinet Doors

Added Latches to Cabinet Doors

Closet Latch

Closet Latch

New Bike Rack

New Bike Rack

12 volt vacuum

12 volt vacuum

CO2 and Smoke Detector

CO2 and Smoke Detector

I also installed a wrap around curtain rod.  Liked the look.

Curtain rod starts at the closet.

Curtain rod starts at the closet.

Curtain rod was installed from the kitchen to the first bend at the front of the trailer.

Curtain rod was installed from the kitchen to the first bend at the front of the trailer.

Curtain rod over Counter to add storage.

Curtain rod over Counter to add storage.

Bed extension

Bed extension

It fits out further if we decide we need it.

It fits out further if we decide we need it.

One wheel had lug nuts, the other was bolted on.

One wheel had lug nuts, the other was bolted on.

Wheel cleaned up

Wheel cleaned up

Rim Painted Brown

Rim Painted Brown

Wheel on the trailer is painted, beside is the one still needing paint

Wheel on the trailer is painted, beside is the one still needing paint

Full sized screen

Full sized screen

Screen cut to size

Screen cut to size

Glued the fabric together

Glued the fabric together

Screen back together and ready to be installed

Screen back together and ready to be installed

Screen Installed

Screen Installed

Screen from the inside

Screen from the inside

Top of door

Top of door

Finishing pieces for the bottom

Finishing pieces for the bottom

Added the last hardware to the bunk railing.

Added the last hardware to the bunk railing.

I experimented with different ways to create small decals, settling on a knife and colored duct tape to make the flames.

Found using a stickers makes a nice template for spray painting.

Found using a stickers makes a nice template for spray painting.

Finishing up the table hardware.

Finishing up the table hardware.

Temporary Air mattress for this summer

Temporary Air mattress for this summer

Locked the bunks in place

Locked the bunks in place

Boler Logo Template

Boler Logo Template

Clamp installed

Clamp installed

Cooler is Clamped and solid.

Cooler is Clamped and solid.

 

Green Boler Rebuild 4

3 comments


  1. Shane

    Great job looks fantastic . May I ask how did you secure the closet and kitchen cabinets to the walls?

    • Thanks. Any furniture that was the original fiberglass was riveted back on as it would have been originally. The wood I used minimum number of screws from out side.

  2. Brent

    I continue to reference your work as I make progress on my Boler. What a great resource! I have painted the exterior, rebuilt the windows, completed the insulation and now I am working on the carpet. Where did you get your carpet? Is it rubber backed/stretchy? I have glued up so carpet (outdoor carpet from box store) but with the curves, I am having trouble keeping wrinkles outs. Once they started they continue to get worse. Any insights on how you completed this task would be helpful.

    Thanks in advance.

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