Don's BushCaddy R-120, The Skunkworks Airplane Factory, N2C

'54 Airstream Cruiser

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1954 Airstream Cruiser

Ok, so the case of metal illness continues.  The airplane is complete and I need another project...what could make more sense than putting all the skill I gained with aluminum to good use?  Debbie and I have always been avid campers.  We got our first trailer in 1985 when Jesse was 4 years old.  It was a 15' Shasta.  Over the years we upgraded in size to a 22', then a 26' and then a 33' Coachman with slide outs.  Jesse got older, paying for college intervened and we went many years without camping but always talked about getting back into it.  Shortly after I started the airplane we bought a 2006 Airstream Bambi (19').  Jesse was going to grad school in North Carolina and my wife Debbie would load up the camper with herself and the dogs and trek back and forth, all by herself, on a regular basis...talk about independent!!

Having the Airstream has been great and it brought back many fond memories so we decided to hunt for a vintage camper, rehab it with modern wiring and plumbing while maintaining as much of the vintage look and interior as possible.  It took several months but right around Christmas 2010 I came across Dan Piper's webiste, http://www.vintagecampers.com.  He had a 1954 Airstream Cruiser listed for sale.  Dan has been a terrific guy to deal with, very straightforward and we quickly put a deal together...the best part is I was able to leave the trailer stored at his shop for up to one year.  

Debbie drove out to Peru, Indiana in October of 2011 and hauled the Cruiser back home...all by herself.  I was actually quite surprised at how good this Airstream looked for being 56 years old.  Our only real criteria upon beginning the hunt was that the exterior needed to be in relatively good shape, so we got a real bonus on this one...the interior looks terrific and we will be able to reuse almost all of it.

We finally got started on this project in Novermber, 2011.  The plan in place right now is as follows:  Remove the interior, lift the exterior shell and remove the floor and replace it, replace the axle and electric brakes, replace the belly pan, upgrade all the plumbing to pex tubing with a new water heater, upgrade the elctrical system with upgraded 110 volt wiring, a new 12 volt system and strategic LED lighting.  When we redo the interior some of the interior aluminum panels may get replaced with wood...not really sure on all these details yet.  The way this webpage will work is the most recent work will appear at the top so if you want to look chronolgically go to the bottom and work your way up.  

The trailer is 26' long and has a perfect layout for us.  Upon entering the door there is a large living area where we plan to put a full size leather couch and table with some chairs.  The bedroom area is at the rear and has a two bunk setup, which we like.  After sleeping in a king size bed for years, the small trailer double beds just don't cut it.  The two bunks will be big enough to allow us both room to stretch out.  The bathroom probably will be expanded just a bit because we do use the shower in our trailer all the time.

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Jacking up the shell

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Jacking up the shell

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Jacking up the shell

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Debbie Hard At Work

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Wheel well trim saved

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Cruiser in the Hangar for winter work, Nov 2011

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Jacking up the shell

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Jacking up the shell

Drilling out solid rivets is easy.  Most people make the mistake of trying to drill all the way through while what you really want to do is snap off the head.  So using a 1/8th or #30 drill bit, drill a hole about 1/8" deep.  Then insert the 1/8th punch in the hole and snap off the head.  Use the punch again with the hammer to bang out the shop head of the rivet.  This method almost always keeps you from compromising the size of the hole.

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Tools needed for drilling solid rivets

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Drill a hole 1/8" deep

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Head Snapped Off

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After Drilling

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Interior demo underway.

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Bought the Cruiser, Dec 2010

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All Metal, Wheels, Floats Or Skis, Robust Bushplane