New project, different to the last one!!

[hayleyandzeb]

Hello all,

sorry if this is a super noob query, I have only done 1 caravan restoration so far and have just come across my next project which is significantly different to the last. I'll get straight to my question...

The caravan I have just purchased has what looks like about 12mm thick ply walls with no framing. Cabinets are framed out on the inside but there is no second skin so to speak and no timber frame in the walls. i.e. the piece of ply on the outside is the same as the one on the inside..

I haven't seen this type of construction before, all the vans I have seen previously have has about 6mm on the outside with framing and then 3mm odd on the inside.

additionally, the middle section, i.e. the front, roof and back has framing as I have seen before with about 3mm ply on the inside but the outside has been entirely replaced with aluminium sheeting. The ally profile looks earlier than mid 60's...

I intend to replace the middle section and was wondering what I should use? I am guessing 6mm marine ply is a good bet?
also, I was wondering if anyone else has seen a caravan with thick side walls and no framing?

other than that, the van has a beautiful kero/gas fridge, an almost perfect stove and a gas light and is in excellent condition. the original owners son tells me it has been in the shed for about 25 years and thankfully the upholstry was stored inside a house and has survived in fantastic condition.

based on info from the origional owners son, the van should be early 50's construction.

If anyone can shed some light on the construction that would be extremely helpful!

thanks in advance!

zeb

[DC3Td]

Gday & welcome. Best to have a spar with p/bucket & show us some pretty or not pics.That way we can see what (to some degree at least) is going on.

[Roehm3108]

Agree with DC3td. This is the Teardrop way of construction. Is that what you've got or a full van with headroom?

[Geoff & Jude]

hi zeb

our 16' aerolite uses the same style of construction.

no inner lining but only 3mm, 3 ply walls which are strengthened only by the framework and the cupboard hardware.

at only about 600kg, the design makes for a very light, mid sized van.

geoff 'n jude

[hayleyandzeb]

Hi everyone, thanks heaps for your replies, I'll take some shots and put them up as soon as I have picked it up. it's not a tear drop but it is quite a small van.


z

[akeepsake]

Gidday Hazeyandzeb and welcome to the forum! This method of construction you described is quite common and as already stated is used to keep the weight down ( and the cost) the frame as you stated is front, back and roof and the solid sides act as bracing combined with interior cabinetry to hold it all together
Pics will be good but I would stick to 12"" marine ply replacement (or as close as you can get to original size to repair damaged section)
I Have a 12' Pheonix van that is exactly the same construction as your description which I need to replace the whole side . Unfortunately times have changed and large single sheets aren't available anymore so I will join sheets and brace the joint on the inside with covers strips of timber mould
Anyway all the best and get those pics up !
Cheers Andrew

[kyliedwyer]

Hi Zeb

I just purchased a 1960's skyline and it is the same we constructed one new wall yesterday I will get some pictures up asap to show everyone how we did.

kylie

[hayleyandzeb]

Hey Andrew, thanks for the info, the sides are in great nic and do not require replacing, It's the whole middle section that needs replacing. The origional plywood exterior on the middle section has been completely removed and replaced with ally sheet. I am intending to remove the ally sheet completely and replace with ply. The problem is that bnecause the whole section has been removed, I do not have any ply to reference for correct thickness.

Maybe someone can give me an idea of how thick the exterior sheet should be for the middle section (front, roof and rear)? as I need to replace the whole thing, it will need to curve around so I think 12mm will be too rigid and significantly overkill for this job?

z

[akeepsake]

Feb 2, 2015 16:32:29 GMT 10 hayleyandzeb said:

Hey Andrew, thanks for the info, the sides are in great nic and do not require replacing, It's the whole middle section that needs replacing. The origional plywood exterior on the middle section has been completely removed and replaced with ally sheet. I am intending to remove the ally sheet completely and replace with ply. The problem is that bnecause the whole section has been removed, I do not have any ply to reference for correct thickness.

Maybe someone can give me an idea of how thick the exterior sheet should be for the middle section (front, roof and rear)? as I need to replace the whole thing, it will need to curve around so I think 12mm will be too rigid and significantly overkill for this job?

z

Ohhhh so you mean the front and the back Are you sure they weren't originally Ali sheeting ?? Better get some pics up!
Cheers Andrew