Ella Walter
The belly pan of an Airstream trailer is a series of metal sheets on the underside of the trailer, riveted to the frame. It protects the bottom of the trailer from rodents, the elements, and wind resistance. Removing the belly pan involves drilling out the rivets and separating the metal sheets. When replacing the belly pan, it is important to ensure proper curvature and overlapping of the new metal sheets. Additionally, sealing certain areas while leaving others unsealed can help manage water escape in case of leakage.
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What You'll Learn
Removing the old belly pan
Prepare the Work Area:
Before starting, ensure you have gathered all the necessary tools and safety equipment, such as a power drill, drill bits, plastic scrapers, razor blades, and eye protection. Lay out drop sheets or a tarp underneath the trailer to catch any falling debris or metal shavings.
Remove Rivets and Panels:
Begin by removing the rub rails, which are the trim pieces that cover the seams of the side panels and banana wraps. Carefully drill out the pop rivets or "buck" rivets that hold the rub rails in place, using a drill bit of the appropriate size, typically 1/8" or 3/16". Take your time to avoid breaking drill bits. Once the rivets are removed, use a plastic scraper to gently break the seal between the panels and the trailer, being cautious not to scratch the soft aluminum surface. Then, use a plastic razor blade and aircraft remover to clean up any remaining sealant.
Detach the Belly Pan:
With the side panels and banana wraps exposed, proceed to remove the aluminum pieces that comprise the belly pan. Drill out the rivets that hold these pieces in place, being mindful of aluminum debris that may be released during the process. As you work, pay attention to any wiring or brake connections that may be affected, as accidental detachment can occur. Once all the rivets are removed, carefully lower the belly pan and set it aside.
Inspect and Clean:
With the belly pan removed, inspect the underside of the trailer for any damage, corrosion, or signs of critter infestation. Remove any dirt, debris, or insulation that may have accumulated. Scrape away old sealant and clean the area thoroughly, ensuring it is free of residue.
Prepare for Reinstallation:
Before installing the new belly pan, address any necessary repairs or modifications. This may include welding framing members, treating the frame, replacing the floor, or installing new tanks and plumbing. Ensure all issues are resolved and the trailer is ready to receive the new belly pan.
Remember to take your time during the removal process and follow safety precautions to avoid injury and potential damage to your Airstream. It is recommended to have a helper or two to assist with holding and drilling, especially when working with large pieces.
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Ordering and cutting new aluminium pieces
Ordering Aluminium
When ordering aluminium for your Airstream belly pan, consider the type and thickness of the aluminium, as well as the dimensions required to cover the necessary areas. Several sources recommend ordering from AirParts Inc., praising their prices, product range, and customer service.
For the main centre belly section, you may need a 48-inch wide roll of .025-inch 5052 H32 Airstream Belly Pan aluminium. This type of aluminium is also suitable for forming pieces that go up under the front skin, eliminating gaps that allow dust and rocks to enter.
For the banana wraps, which are the curved sides of the belly pan, consider using .032 2024T3 Alclad Airstream aluminium. This type of aluminium can be polished to a high shine, matching the aesthetic of the Airstream shell.
Cutting and Shaping Aluminium
Before cutting new aluminium pieces, it is essential to use the old pieces as templates. Trace the outline of the old piece onto the new aluminium sheet with a marker that can be easily removed later, such as a Sharpie.
The next step is to create a slight curve in the aluminium sheet. Carefully hand-bow the aluminium on the ground, ensuring you don't crease it. This step is crucial for achieving the curved sides of the belly pan.
After creating the desired curve, you can start riveting. Secure one side first, either the top or belly side, and then tightly wrap the aluminium around the corner, riveting the other side. This process is much easier with an extra pair of hands, especially for longer pieces.
Ensure that your pieces overlap properly, with the rear pieces going under the next pieces to prevent wind and rain from entering. Cutting and shaping aluminium can be challenging, especially when dealing with complex curves and angles. It is essential to have the right tools, such as metal shears or pop rivets of different lengths, to secure the aluminium to the frame effectively.
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Tracing and curving the aluminium
Preparing the Aluminium Sheet
Start by laying out a new sheet of aluminium on a flat surface. For an airstream belly pan, you will likely need a sheet of aluminium that is at least 48 inches wide and has a thickness of 0.025 inches. Ensure the sheet is clean and free of any debris.
Tracing the Old Piece
Place the old belly pan piece on top of the new aluminium sheet. Using a marker, carefully trace the outline of the old piece onto the new sheet. A sharpie marker can be used, as it can be easily removed later with acetone.
Bending and Curving the Aluminium
Now, it's time to give the aluminium sheet a slight curve. This can be done by hand, but it requires caution to avoid creasing the material. Carefully bow the aluminium sheet on the ground, applying gentle pressure to create a smooth curve without any sharp bends or kinks.
Riveting and Shaping
Once you're happy with the curve, it's time to rivet the aluminium in place. Start by riveting one side, either the top or the belly side, and then wrap the aluminium tightly around the corner, ensuring proper overlap so that the rear pieces go underneath, providing protection from wind and rain. With the help of an assistant, rivet the other side in place.
Trimming and Final Adjustments
After the aluminium is securely riveted, you can make any necessary trimming adjustments. Use metal shears or strong scissors to cut the aluminium, ensuring a precise fit. Check that all pieces fit together correctly and make any necessary adjustments before installing the new belly pan on your airstream.
Working with curved aluminium can be challenging, and it's important to be cautious to avoid cracking or deforming the material. Take your time, and if you're unsure, seek guidance from experienced individuals or professionals.
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Riveting the aluminium pieces together
Riveting aluminium pieces together is a common practice in aviation, with aircraft frames being assembled using hundreds of thousands of rivets. The process of riveting aluminium sheets is a straightforward one, requiring the right tools and some basic knowledge of metalwork.
Firstly, it is important to ensure that the pieces of aluminium fit together properly, with no gaps or spaces between them. This is essential to creating a strong and secure joint. If there are any gaps, the metal may need to be trimmed to ensure a snug fit.
Next, the rivet length should be chosen carefully. As a rule of thumb, the length of the rivet should be equal to the total depth of the hole, plus 1.5 times the diameter of the rivet. This will ensure a strong joint that can withstand loads.
When riveting, it is best to start at one end and work across to the other side, or to start in the middle and work outwards. This helps to ensure that the pieces are aligned correctly and do not shift during the process.
It is also important to consider the type of rivet being used. Solid rivets are typically used in applications where reliability and safety are critical, such as aircraft structures. The type of aluminium alloy used for the rivets is also important, with various alloys offering different properties. For example, "ice box" aluminium alloy rivets harden over time and must be kept at sub-freezing temperatures to slow this process.
Finally, when fastening the rivets, it is important to place the head of the rivet on the softer of the two materials, as this will result in a stronger joint. Additionally, using a backing washer can help to distribute the load more evenly and improve the strength of the joint.
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Sealing the aluminium pieces
Preparing the Aluminium Pieces:
Before sealing, it is essential to ensure that the aluminium pieces fit accurately. Compare the new pieces with the old ones and make any necessary adjustments. This step ensures that the aluminium sheets align correctly and creates a seamless seal.
Sealing Materials and Techniques:
For sealing the aluminium pieces, you can use products like Trempro and Acryl-R. Trempro is ideal for sealing the top of skirts and banana corners, while Acryl-R is suitable for sealing the rub rail. These products create a watertight barrier, preventing water ingress.
When sealing, ensure that the pieces overlap properly. The rear pieces should go under the subsequent pieces, allowing rain and wind to pass by without entering the trailer. This technique enhances the overall protection of your airstream belly pan.
Sealing the Belly Pan:
Start by sealing the large pieces in the middle, working section by section. Then, move on to the skirts and banana wraps, which are curved aluminium pieces that give the airstream its distinctive shape. Finally, seal the rub rail, which is the outermost part of the belly pan.
Leaving Some Areas Unsealed:
Interestingly, it is recommended to leave the pieces under the trailer unsealed. This deliberate decision serves a purpose: it allows water to escape through the seams if it somehow manages to get inside. This design choice helps prevent water accumulation and potential damage.
Additional Tips:
When working with aluminium, always use plastic scrapers and razor blades to prevent scratching the soft aluminium surface. Additionally, when drilling out rivets, be prepared for aluminium pieces blasting in your face—it's a messy job!
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Frequently asked questions
You will need a power drill, a plastic scraper, a plastic razor blade, aircraft remover, and metal shears or strong scissors.
The original Airstream belly pan was made from .
The Airstream belly pan provides a seal against rodents, protects the steel frame from the elements, and reduces wind resistance.
