1992 Starcraft starlite Rebuild with pics

Discussion in 'Camper Restoration Projects' started by Rhconcepts, Jul 22, 2017.

  1. Rhconcepts

    Rhconcepts Active Member

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    Camper Sold 6/1/2018 For 2000.00
    Im looking to buy a cargo trailer to convert.
    Hey everyone, this is going to be a copy of my old post. The old one lost all the photos thanks to photobucket and the crazy charges they are asking to link photos. I might add in a few extra pictures as I repost this. I will do my best to keep everything in the order as I rebuilt the camper.

    Here is the link to the old build log, I might try to edit the log to get the photos back up.


    I just got a 92 Starcraft and this is my first pop up. It needs roof, back wall repair and I will be redoing the inside floor. I won't be asking questions her just showing pictures of what I'm doing. If I'm not doing something right please let me know. Like I said this is my first camper and I don't even know how they are made. Here is a list of things to be fix in this order.
    1. The back side roof wall and the driver side roof wall. Rotted wood.
    2. The back wall and new taillights, one is broke and letting water in.
    3. The floor shows discoloration in the back maybe from the taillight.

    The camper is all done. I added videos of the camper below in case you don't want to look at the pictures.

    D3C41959-D716-43A2-BEA5-F82B3189E5F1_zpsmarvcadt.jpg 24490613-31C9-4AF5-A77A-D72C9FF70027_zpsftlajgeo.jpg F7FB712C-6797-47D4-A5F1-E2336BABE07F_zpssze5qtd2.jpg 40941C9C-A02D-43A4-9D05-B44346C2B47F_zpswxvezpvz.jpg 54A5DF20-391B-4ACA-B468-4FF6B1206D62_zps29mko7bv.jpg





     
    Last edited: Jun 1, 2018
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  2. Rhconcepts

    Rhconcepts Active Member

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    I found more wood rot then expected

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    Last edited: Jul 24, 2017
  3. Rhconcepts

    Rhconcepts Active Member

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    So tonight I got the lower trim and seal off and it looks like I can use the trim again but I will need a new seal.

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    I got the one side off but now I'm finding out I need to go back inside and unhook the canvas from the roof :( I'm going to try and find new sheet metal for the side, it will save tons of time on cleaning the old one.
     
  4. Rhconcepts

    Rhconcepts Active Member

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    So it looks like the sheet metal is not long enough to tuck back into the lower seal trim. Someone cut it because it may have been deteriorating and used tons of caulk to fill it in. I started a post asking if fiberglass would work if I rebuilt the roof. Going to look into that more and see if I need a plywood top or can the fiber boards rest right onto the frame.
     
  5. Rhconcepts

    Rhconcepts Active Member

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    Had no one to help me with the roof but I did get it off :) Now I might remove everything to see if the floor can be replaced.

    66A49245-710E-4C8C-8F0F-B3075E4F167F_zpsmygvhags.jpg 42E15F0D-C60F-44ED-BCAF-BF2EF5768F34_zpsrgqswvst.jpg 63EEE200-6F91-4B0C-A204-0997E35DFBD6_zpsikjfo9lk.jpg
     
  6. Rhconcepts

    Rhconcepts Active Member

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    Hard to make this out but this is the underneath side. I want to replace the OSB floor so Im looking to see what needs to come off. All the cabinets are coming out and a new vinyl floor is a must. I did order my 9' long OSB sheet from Homedepot today for the roof, thats nothing they sell in the store.

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  7. Rhconcepts

    Rhconcepts Active Member

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    Im removing the cabinets now and plan on making new ones. It must cost the manufacture about 30.00 - 50.00 to make them. All they are is paneling board with 1/2 x 1/2 boards holding them together. The new floor plan will include a porta potty for my daughter and a real frig not a cooler :)

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    Im trying to clean all the canvas before winter is here. I have one more big one to do outside the rest I can do in the tub.

    0A67A640-1784-4B2A-B428-82EFE2B28A83_zpsynrplwgo.jpg
     
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  8. Rhconcepts

    Rhconcepts Active Member

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    Here is a pic of the cabinets coming out. So far I don't think I'm over my head but the floor is making me think a lot.

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  9. Rhconcepts

    Rhconcepts Active Member

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    I love this page so far but I wish more people would come back and give feed back on the products that they used for the rebuild. The key is to do a rebuild better then the last guy but it's hard to do if you don't know how his turned out after a few years.

    I just about have all the cabinets out and the sides are a breeze to take off. They are held on by the top trim going around the top then staples on the underneath. All the staples need to come out to slide in the new OSB floor and some lines like power and water need to be pulled out from underneath. If I do remove all the walls I might clean up the frame and repaint it. If I can redo just the surface that the OSB will rest on I can do the rest in the spring from underneath it. I'm going with a waterproof OSB because I know it will stay flat and it won't soak up water.
     
  10. Rhconcepts

    Rhconcepts Active Member

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    Walls coming off

    A0FDA936-0D3E-4913-AE0C-6476CE850187_zps2tepckt5.jpg DD50CF5B-908C-4CFF-906B-E037595B76C8_zpst0wwof9b.jpg 37AD2CEA-930D-453E-A8EA-B5353F808BBF_zpsbptdsqbt.jpg
     
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  11. Rhconcepts

    Rhconcepts Active Member

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    This is how I found the screws that held the floor down, its a old trick but it worked great. I only had to look under the floor for one screw.

    I used a high powered computer hard drive magnet

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  12. Rhconcepts

    Rhconcepts Active Member

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    I got the frame cleaned up and I applied one coat of the R-O rust reformer. I have to wait 3 days then I can paint it with R-O acrylic enamel, went with that because it says its made for cars and trailers. The reformer sure makes it look nice I cant wait to see how it turns out.

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  13. Rhconcepts

    Rhconcepts Active Member

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    After this is done I will be picking up the marine grade plywood for the floor. I think I'll use that for the roof walls as well. But 5/8 is going to be to thick to fit back in the roofs seal trim. 1/2 looks about the right size but I hate to buy 2 sheets of 5/8 for the floor a 2 1/2 sheets for the roof. Feedback on using 1/2 for the floor would be helpful. If I can get away using 1/2 for the floor I would only need to buy 3 sheets.
     
  14. Rhconcepts

    Rhconcepts Active Member

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    started working on the walls

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    And lights and the new vent came today. Im using leds for the inside and i will be getting a led bulb for the porch light. That will take the light from 103 lumen up to 540 and lower the amperage down from 1.4 to .4

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  15. Rhconcepts

    Rhconcepts Active Member

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    I picked up the vinyl floor sheeting at Lowes today for 60.00 I wanted something darker but this shroud be fine. I would take a pic but it's all rolled up
     
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  16. Rhconcepts

    Rhconcepts Active Member

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    Im only doing this to take her camping. Im doing the pop up because she has crohn's disease and down syndrome so the plan is to have a porta potti built in the camper for her.
     
  17. Rhconcepts

    Rhconcepts Active Member

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    Marine grade plywood 50.00 a sheet :( I wasn't looking forward to buying it. So today at the store they couldn't read the bar code off the 2 sheets and she asked what it was so I said 1/2 marine grade plywood and she pulls up 13.00 a sheet. She looks at me and says is that ok? what am I going to say NO? lol so for 32.00 I have my floor.

    Here I used the router to cut down 1/4" and in 2"s. I will glue the to together to help seal water out.

    AF8CD3B3-E280-40BC-A127-76EF77541C50_zpsjvmbdkpu.jpg 47E76146-7228-440C-9DDC-8ADF5281D58F_zpspsug6lpw.jpg CA9A5A0C-954C-430A-99FB-22B9F21E29D0_zpsmh9pspzn.jpg
     
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  18. Rhconcepts

    Rhconcepts Active Member

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    I started to stain or paint the underneath with a 10/25 year waterproofing stain. It should last longer then I need it to :)

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  19. Rhconcepts

    Rhconcepts Active Member

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    Well I got the two sheets glued together and wheel wells on. I had to order new screws to hold the floor to the frame so im done until Friday. I ordered some #8 stainless steel tapping screws but I'll still pre-drill to help speed it up

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  20. Rhconcepts

    Rhconcepts Active Member

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    Well the floor is done and the heater will stay on for 24-48 hours so it can dry. I was very happy with the results and how straight I got it.

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