68 Overlander – Main Internal Lighting

August 15, 2014 / Overlander 2, Project Updates /

Along with the new inner skin, wiring has been added for the main lighting. I am using 5 watt led lamps and custom built switches. Each switch is fitted with a Perspex spacer, illuminated with a red and blue Led giving a cool halo of light.


68 Overlander – Fitting the new inner skin

July 5, 2014 / Overlander 2, Project Updates /
2014-07-15 11.21.01

A new inner aluminium skin is being fitted. We are using skin pins to hold the panels in place while rivets are fitted, but its still a two person job. Fitting the skin will require over 1000 rivets.2014-07-04 15.19.08 2014-07-14 17.26.58 2014-07-14 18.31.52 2014-07-15 15.06.04 2014-07-15 11.20.51


68 0verlander – External Skin Repairs

June 17, 2014 / Overlander 2, Project Updates /

There were several holes left by the removal of the old furnace and water heater. I have patched each hole with matching aluminium. Once the new rivets are ground down and the patch polished the result is quite pleasing and I think reveals some of the history of this airstream.2014-05-27 12.11.14 2014-05-27 13.39.21

68 Overlander – Skin Insulation

June 17, 2014 / Overlander 2 /
2014-07-03 13.16.42

The insulation we are fitting is a multi-layer foil which is glued to the inside of the skin and carefully sealed around all edges to eliminate any condensation problems.


68 Overlander – Floor and Insulation

June 11, 2014 / Overlander 2, Project Updates /
2014-06-04 15.30.32

With the chassis repaired, cleaned and painted the insulation can be fitted. I am using  25mm cellotex fitted between the chassis rails with the edges taped to protect the top of the chassis from any water trapped under the floor. 2014-06-04 15.30.32

Here you can see the insulated tub in the new rear chassis which houses the grey water tank

2014-06-10 15.24.33

The new flooring being fitted is 18mm phelonic plywood. Waterproof and very tough.

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68 Overlander – Polishing stage 1

June 10, 2014 / Overlander 2, Project Updates /

Removing the clear coat has revealed a very clean skin, largely protected from oxidisation. The first stage polish, using a course polish and a stitched mop generates a deep shine – and a lot of black muck!

68 Overlander – Stripping the clear coat

June 7, 2014 / Overlander 2, Project Updates /

Before the skin can be polished the old clear coat lacquer will need to be removed. I am using a water based paint stripper which is applied as a gel and after allowing time to react is removed with a pressure washer. This is a environmentally friendly product so the residue is harmless.

68 Overlander – Chassis Repairs

May 29, 2014 / Overlander 2, Project Updates /

Following the floor removal it was clear that the rear chassis had some damage due to a water leak which had soaked through the floor into the belly pan. Thankfully the forward chassis was undamaged. We decided to cut away the rear chassis and have a new section fabricated by www.performancefabrications.co.uk. The new chassis section was fitted along with some new outriggers and the whole chassis rust treated and painted.


68 Overlander Strip Down

May 20, 2014 / Overlander 2, Project Updates /

It took us no time to strip out the original interior, followed by the interior skin, insulation and floor. What we found was a rat nest, almost literally! Behind nearly every panel were mice runs and most of the electrical cables had been chewed – good job its all being replaced! Thankfully the mice were no longer resident.

68 Overlander – Back to base

May 18, 2014 / Overlander 2, Project Updates /