Green Boler Rebuild 4

 

 

It is finally time to paint the trailer, I plan to spray it (later I roller another and would roll it next time).  Without the space to spray it, we had a offer to use a space at a relatives house, so we packed up the trailer (wrapped it to keep it clean) and drove to the mountains.

Having never attempted anything like this before, it should be fun.

The plan is to use a tent to paint in, it keeps the sun off the wet paint, and random things from falling / blowing onto it when it’s wet.

The trailer still wrapped the next morning

The trailer still wrapped the next morning

A little more sanding and it is ready to go.

Ready for Paint

Ready for Paint

We also decided to spray a truck while we were at it.

 

$50 paint job costs $130 with sand paper, tape, paint thinner and all other supplies.

$50 paint job costs $130 with sand paper, tape, paint thinner and all other supplies.

First step was to primer the whole thing, a couple coats.

Primer on Trailer

Primer on Trailer

I picked up a spray gun for this project on sale at princess auto, around $15.

Spray Gun I used

Spray Gun I used

I picked up the paint from Industrial plastic supply, as seen below.

Top can was Primer, Middle White, Bottom Green (is different to make the color i wanted)

Top can was Primer, Middle White, Bottom Green (is different to make the color i wanted)

For a couple of the detail parts I used brown spray paint.

Brown paint used

Brown paint used

I also grinded off the tongue jack, as I have not yet been able to get it to work.

Old Boler Tongue jack

Old Boler Tongue jack

The trailer freshly painted I rolled it out and got ready to install the windows.

Boler is Painted

Boler is Painted

The side windows were ordered from Sunview industries.

Side window going in

Side window going in

I threw a tarp over it at night, just in case it rains.

Covered for the night

Covered for the night

Door and door window installed

Door Installed

Door Installed

After breaking a couple pieces of plexiglass, I got the local glass shop to cut it.

 I ended up getting a more flexible clear plastic for the front window, the only problem is at freeway speeds it flexes so much it blows into the trailer, requiring the rock guard to be on when driving.  

Getting the Front and Back window installed

Getting the Front and Back window installed

The new front window installed.

Windows are in

Windows are in

Adding the LED tail lights and licence plate.

Installed the taillights and license plate.

Installed the taillights and license plate.

Adding the vents

Adding the vents

Vents Installed Boler Trailer

 

I picked up some door trim from Canadian Tire, and used it to trim up the front rock guard.

Adding some trim to the Rock Guard

Adding some trim to the Rock Guard

The hardware to hold the rock guard on was purchased from Scamp trailers.

Adding the hardware to the Rock guard.

Adding the hardware to the Rock guard.

Almost installed

Almost installed

I picked up a LED light / grab handle for beside the door on the Boler.

Outside Light

Outside Light

A huge storm came through, thoroughly testing the seals just installed.

Had to stop working as it started to rain.

Had to stop working as it started to rain.

RV Level installed.

RV Level installed.

Level beside Door

Level beside Door

I did not have the metal piece the door latches to, so I found some scap metal and made one.

Building the door Catch plate

Building the door Catch plate

Door catch installed

Door catch installed

Belly Band door stop

Belly Band door stop

While driving home we discovered that we needed to have the rock guard on the trailer, because the plastic front window was too flexible, so we tied it on for the drive home.  (plexiglass front window would not have this problem).

Rope holding the rock guard on.

Rope holding the rock guard on.

To install the wrap around curtain rod, I used butyl tape to seal the bolts.  I bolted the bolts to the fiberglass shell, then added another nut to hold the curtain rod on, this way I could take the curtains down without messing with the seal.

Hardware I used

Hardware I used

Bolt on the Shell

Bolt on the Shell

Bolt on Inside

Bolt on Inside

Marked inside with tape.

Marked inside with tape.

Installing wrapping curtain rod

Installing wrapping curtain rod

Above the dinette I installed a LED battery powered light.

Light on ceiling

Light on ceiling

I added a smoke detector and CO2 detector to the top of the closet, both run on their own batteries.

Screwed on the smoke and CO2 detectors.

Screwed on the smoke and CO2 detectors.

I picked up a new tongue jack for $20 at Costco and bolted it on.

Moved Tongue Jack forward.

Moved Tongue Jack forward.

Installing the hardware on the trailer to hold the front rock guard on.

Rubber spacer, Rock Guard hardware.

Rubber spacer, Rock Guard hardware.

After cleaning up the emblem, it still didn’t look great, so I painted it.

Emblem Primered

Emblem Primered

Chrome Paint on Emblem

Chrome Paint on Emblem

Boler Emblem Installed

Boler Emblem Installed

The current vents are not enough for the propane cooler, so I picked up some larger ones.  (The propane cooler turned out to be a poor choice)

Marking the Trailer

Marking the Trailer

Painting the Vents

Painting the Vents

After painting and installing the vents, I found vents that where already the right color at the store.

Installing vents Boler trailer

All done

All done

Not sure how to install the propane tank, I made this.  After finding out later I had the right parts, I installed them, they work much better.

Propane tank on the tongue.

Propane tank on the tongue.

Close up

Close up

To improve the fit of the door, I added washers to the hinges in spots to create the right curve.  Can’t see them, but it did make a difference.

Added a washer to the hinge

Added a washer to the hinge

With the bottom of the door still having a little gap, I decided to add a magazine rack to the door, to help pull the door into place.

Wood to hold door shape

Wood to hold door shape

Wood installed

Wood installed

I painted the rims brown for now, as rims are still an unnecessary expensive.

Painting boler rim

 

I made a wood piece and brackets for the bottom of the door, to finish sealing the gap.

 

Wood piece to close gap

Wood piece to close gap

Profile shot

Profile shot

Installed

Installed

Metal brackets on top to help hold it.

Metal brackets on top to help hold it.

Molding to finish it off

Molding to finish it off

For marker lights I picked up the smallest LED ones I could find, took the mounting ring off to make them smaller and cleaner looking.  Then added my own bolts to mount them.

Right is modified light

Right is modified light

I had a need to flame something, but big flames on the trailer seemed to be a bit much, so I cut out little ones that came from the marker lights.

Marker light Installed

Marker light Installed

I used a piece of curtain rod to make the roof support, this matched the wrap around curtain rod in the trailer.

Roof support

Roof support

It was finally time for our first trip with our camping trailer, however after driving for a couple hours the frame broke.  It was the same price to get it towed home as it was to get it towed to the yard and welded up.  With this we headed home, no camping this weekend.

Frame Broke

Frame Broke

I turned out it broke right where the last repair finished.  ( 14 months later it broke again where this repair stopped, should have sucked it up and built a new frame to start with).

Getting the trailer home I started working on the awning.  I plan to make a nice awning eventually, but for now I wrapped a tarp around a rope and cleaned up a couple of old tarp poles to hold it up.

Awning Rail Installed

Awning Rail Installed

To tighten the awning I found a scrap of metal and made a couple of pieces to hold it tight.  Then I painted them in glow in the dark paint.

Left scrap metal, Right the pieces made from it (4 in the end)

Left scrap metal, Right the pieces made from it (4 in the end)

Test Fitting the Awning

Test Fitting the Awning

Glow in the dark paint so we can see the ropes on our awning

Our Boler on our First Camping Trip!

Our Boler on our First Camping Trip!

The awning worked great!  Next it was time for a 12 volt system and a solar panel.  I decieded to go with a jump pack, as it is small and comes with all the extras required to charge it from the solar panel, 120 volt.  The solar panel and jump pack came to just less than $100 at walmart.

Battery and Solar solution

Battery and Solar solution

We also use this solar lamp from Ikea, at $10 it is a great addition for lighting up the picnic table at night, or inside the trailer.

Solar Light fro Ikea

Solar Light fro Ikea

1974 Boler Mitsubishi RVR towing

 

My wife did a great job sewing up some curtains for the trailer, adding some color to the inside and keeping it dark when sleeping in.

New Curtains

New Curtains

Camping I noticed the trailer frame twisted on just one front tongue jack and 2 rear jacks, so I picked up enough to ensure I had 4.  This made a huge difference.

Boler upgrades from 2 to 4 Stack Jacks to stabilize

With more summer it was time to get out and test all the new changes.

13 P4 Dinosaur Provincial Park Alberta Canada Boler camping

Boler Set up

Boler Set up

With a 12 volt battery on board I wanted to use LED light that run on it.  I already had puck lights in the trailer.  I got a suggestion on a forum to use a cell phone charger to make a voltage adapter so I could run the lights off the 12 volt system.  This worked great for a while, but the LED lights started to fail after a while.

Changing the voltage for the LED lights

Changing the voltage for the LED lights

Made a hole for wires, and glued in two bolts so I could mount it.

Made a hole for wires, and glued in two bolts so I could mount it.

Stripped down LED lights with bolts added.

Stripped down LED lights with bolts added.

One of the best modifications was adding usb ports, as so many lights, fans, tablets, cells and other electronics can run off of these, and at a $1 each it costs nothing to add.

Marking out usb outlets

Marking out usb outlets

USB outlets installed.  Ikea bin fit snuggle in the sink for extra storage.

USB outlets installed. Ikea bin fit snuggle in the sink for extra storage.

Wiring still needs to be cleaned up and hidden

Wiring still needs to be cleaned up and hidden

One issue we had, was when camping our keys, flashlight and such clutter.  With shelves in the closet the space at the top has been wasted, so I added another shelf and cut a hole to make use of this space.  This did wonders in keeping the trailer neat when camping.

Cut the holes in the Closet

Cut the holes in the Closet

Trimmed up the opening

Trimmed up the opening

Finished Access Hole

Finished Access Hole

Top shelf in the closet

Top shelf in the closet

New wood parts drying

New wood parts drying

Attending our first fiberglass trailer meet was great fun, need to go again.

The boys are still where the buttons

The boys are still where the buttons

One challenge we have had is heating the trailer, a furnace takes up too much room, and a small off grid solution has been a tough thing to find.  I decided to experiment with a candle heater.

Testing a candle powered Heater

Testing a candle powered Heater

Parts I found

Parts I found

Testing it in the trailer

Testing it in the trailer

I had started a rack on the door, and although it had fixed the gap at the bottom of the door, I never finished the storage part.

13 P2 Boler door storage and sag fix 13 P1 Boler door storage and sag fix 13 P3 Boler door storage and sag fix carpet

Wood Sink cover

Wood Sink cover

Under Side of cover

Under Side of cover

13 P5 Jasper National Park Alberta Canada Our Boler traveling

 

In our move I lost one of the Boler emblems, at the suggestion again on an online forum, I molded a new one.  this was much easier than I would have expected.

The kit I started with.

The kit I started with.

Mold curing

Mold curing

The mold is done

The mold is done

First one out, another curing in the mold.

First one out, another curing in the mold.

After trimming and a light sanding

After trimming and a light sanding

New plastic logo beside original

New plastic logo beside original

As camping season approached I decided I should learn to repack the bearings, and important skill for anyone with a trailer.

Remove Cap

Remove Cap

At the Boler meet, at the end of the last camping season I lucked into some red cushions for the bed of our Boler.  However when picked up a red boler, and threw out it’s cushions, putting the red cushions in it only made sense.  so when I went to pick up the foam (from Ikea) for the Red Boler, I also picked up enough for our bed and the boys bunks.  Again using a bread knife to cut it out.

The plan was to make cushions, but having not used the table I decided to make one solid mattress

IMG_3328

I used a knife from the kitchen to cut the foam

I used a knife from the kitchen to cut the foam

Foam ready to cut

Foam ready to cut

Foam cut

Foam cut

The bed was comfortable at first, but in the morning I was sore, so I picked up a couple of things to try and make it better, it didn’t help much though.

Padding added

Padding added

 

Green Boler Rebuild 5

7 comments


  1. siobhan

    when we did our cushions, we used a 6″ high density foam ordered out of foam factory, with shipping for all of the cushions, only $400. Can’t believe how great they sleep, like a memory foam mattress

  2. Lou

    Can you tell me where you got your U shaped trim for the rock shield and such? And the hardware for your rockshield?
    As well what did you use for the door seal–the rubber.

    • The trim around the door and rock shield is black trim (also comes in chrome) to go around car doors as a custom option. It was purchased at Canadian Tire. The other option can be purchased at an automotive glass store.

      The door seal was purchased from scamp, but is the same foam you can buy at home depot. I looked for a while for a rubber option, but reluctantly when with foam. The foam works great, and has lasted 3 years so far.

      I have the hardware for the rock guard, but it was in rough shape, so I ordered a kit from scamp.

  3. gabriel neculau

    How did the green floor paint is performing after a few years on the road?

    • The paint has a few chips in the front, but no worse than other trailers I have seen. It was not quite as bright as it once was, but I wiped it with a magic eraser last week and it is again bright. I am happy with the result, although the white paint on the top has held up better.

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