Tuesday, September 8, 2009

1968 Airstream Retrofit Window Installation

Our 1968 Airstream arrived with 4 Jalousie windows that I believe, because of the wooden frame, were not original. They were dilapidated, falling apart, and none of the hardware was operational. After looking into replacement windows for an Airstream I realized we might vastly improve the original single-glazed window with a modern dual-glazed, insulated window. We were lucky because our 1968 Airstream was the last year before Airstream switched to the rounded corner window, thus allowing us to use a modern aluminum frame window designed for a conventional building.
I began by removing the Jalousie window sashes, wooden jamb, and then cut away the aluminum fins all the way around the window. The exterior side at the top had a hinge that ran the width of the window. From the inside I sliced the hinge from end-to-end, removing the articulated half that attached to the glass. I used a Dremel tool at the ends where the corners were too tight for my grinder to fit. I left the remaining piece of the exterior hinge in place which served as a typical Z-bar or window flashing.


Cutting the flange

I used a file to clean up the edges; an easy task with the relatively soft aluminum.



Here's a step I should've photographed more thoroughly. Because the new window was 3/4" thicker than the original I had to attach an additional piece of aluminum to the window where it would protrude inside past the original frame. I used a piece of 1" x 1/4" channel, cut to the window height, and attached it with rivets, in keeping with the original Airstream assembly techniques.

After removing the sash from the new window, I insert the frame. I had measured it close enough that the frame fit snugly with just enough room for minor corrections if the rough opening (which wasn't really rough) was out of square. I removed the top screw on the jamb side of the awning hardware.

The original awning hardware screw

I drilled through the hole where the original screw was through to the original window frame. I can't remember what size drill bit I used, but it was big enough for a #8 screw to thread into tightly. Check out my huge Popeye forearm.

I replaced the original small screw with a #8 x 1" Stainless Steel screw that went through the new window jamb and into the original frame. I did this on both sides, at the highest and lowest screws on the awning hardware.

Near the bottom of the window I drilled another hole for the #8 screw.

I tapered the hole with a countersink.

The tapered hole.

By the way: I wouldn't bother trying to level the window as you would in a typical house installation, since the trailer itself may not be level. However, I would try to make it square. Also, you may want to put a couple of additional screws at the top, but they need to be much longer, because there is a larger space between the new and existing frames. Do not put screws in the bottom, as this increases your chances for leaks. The weight of the sash hangs on the side frames. The top and bottom bare no weight.

I inserting the sash.

Both the sash and frame get masked, for clean caulking lines.
I can't remember exactly what caulking I used, but it is from the Sonoplast family. I used the aluminum color, of course. I caulked the entire perimeter, leaving a small weep hole at the bottom left and right corners (which, because of the angled wall, may not work).

The tape has been carefully removed while the caulking is still a little wet (after about 1/2 hour). A beautiful, insulated, dual-glazed window with modern awning hardware, that works great!

The window is an IWC 21-1/4" x 39" Aluminum Block Frame Dual Glazed Low-E Glass Awning Window, approx $300 plus installation.

Tuesday, August 18, 2009

AIRSTREAM Renderings

I finally started rendering the 1968 Airstream. Kind of complicated as rendering shapes goes.
Didn't get to the bathroom yet, and may not, since it probably won't change.





Here you can see the rear left side (on the right) which includes a small closet, and bench/shelf that covers the left wheel well.


Above is the rear right side (left). At the front is a seat, or shelf, which covers the existing wheel well. Moving towards the back we see 3 curved shelves, 3 drawers, a desk area, and fridge.


The view from the back to the front. An IKEA sofa bed (gotta save money somewhere) between a pair of matching shelves/cabinets.

Tuesday, August 11, 2009

An Entire Life's Dream (The Airstream Story)

Hi Everyone, it's Josh's wife Jen here... I thought I'd share some images from the 1968 Airstream Manual. I adore these images, and how they illustrate the Airstream way of life.



Here's an excerpt from the Wally Byam Creed, (Founder of Airstream, Inc.) -- "In the Heart of these words is an entire life's dream. To those of you who find in the promise of these words, your promise, I bequeath this creed... my dream belongs to you."

The Airstream Creed:
To keep alive and make real an enduring promise of high adventure and faraway lands...of rediscovering old places and new interests.

To open a whole world of new experiences... a new dimension in enjoyment where travel adventure and good fellowship are your constant companions.

To encourage clubs and rallies that provide an endless source of friendships, travel fun and personal expression.

To lead caravans wherever the four winds blow...over twinkling boulevards, across trackless deserts...to the traveled and untraveled corners of the earth.

To play some part in promoting international goodwill and understanding among the peoples of the world...

To strive endlessly to stir the venturesome spirit that moves you to follow a rainbow to its end...and thus make your travel dreams come true..."

Really quite lovely, don't you think? Enjoy...













Airstreams all around the world...


Airstream Rally -- can you believe how many are pictured?!








Yes, it's true. There are some days that I dream of being this woman...











"The Airstream Story doesn't end here... only the words and the pictures. It is only the beginning for you; the beginning of a more meaningful way of life that will open a whole new world of travel adventure..."

Friday, August 7, 2009

Uncle Larry's Nightstands

Here's a couple of walnut nightstands in progress. Designed to match a bedroom set from the 40's or 50's. Not really sure when they were built. Some details were included, such as the leg taper and fluting, while other details were changed, like making them 3 legged, and adding a drawer at the bottom where there would have been nothing. Should be done on Monday.




Wednesday, July 29, 2009

Day 13, July 26th, Moon Germs

After returning home, and a day off, Jen, Vince & I took a field trip to the USS Hornet, at the old Navy Base, in Alameda. Just a 5 minute drive from our home, the USS Hornet was celebrating the 40th Anniversary of the Apollo 11 Moon Landing. We missed the Saturday event with Dr. Buzz Aldrin (I wish I could be called "Dr. Buzz") but still had a great time. It was my 3rd visit, but this trip had new meaning. Besides the other important chapters in the ship's history, the Hornet had the honor of picking up the astronauts after they returned from the moon, and splashed down in the ocean. Upon their return to Earth, the astronauts were quarantined for 21 days, for fear of spreading "moon germs", in a custom built 1968 Airstream, the same year as ours. Fascinating. It was great to see how similar the amenities were in the Airstream Mobile Quarantine Facility. Same sink, cabinets, curtains, & toilet, plus a few things we didn't have, like the airplane seats and conference table. Pretty cool.
After we returned home we listened to the 1972 CTI recording, Joe Farrell's "Moon Germs"; a quartet featuring heavy hitters Herbie Hancock, Stanley Clarke, and Jack Dejohnette. You know that's good.

Those of you familiar with George Lucas's THX-1138 may recognize the
Posey Tube as one of the underground expressways in the film.
For us it's just how we connect Alameda.



Colonel Vicente Aello and Captain Skidmarks return from Mars



The 1968 Airstream Mobile Quarantine Facility being loaded
onto the Hornet prior to Astronaut recovery





Apollo 12 capsule. The Airstream was used to quarantine astronauts
after this mission, as well.






Vince found ashes in ashtrays of these seats in the Airstream.
Smells like somebody's smoking moon rocks.




The Airstream MQF in some of it's glory.