Streamline Aluminum Trailers: Restoration & Modification

INTRODUCTION

Despite Airstream being the first brand to come to someone’s mind when discussing shiny vintage campers, there are many alternatives to choose from, like this polished Barth.

When I started this book, the only camper I planned to include was a 1952 Airstream Cruisette. As soon as writing began, however, it was apparent that more than one restoration should be featured to cover everything you need to know to resurrect an old camper. Besides the Cruisette, I included a 1950s Boles Aero Ensenada and a 1970s Airstream Sovereign.

Boles Aero Ensenada

Pulled from the palm desert where it sat for decades, the Boles Aero Ensenada required a couple of days and a well-equipped tow rig to recover. Sometimes retrieving a camper requires traveling to remote areas and using minimal resources to fix it. Getting this gem from a sedentary state to roadworthy status required jacking it up in the sandy desert to remove the wheels so the dry-rotted and square tires could be replaced. Luckily, it did not have split rims, so the wheels did not need to be replaced.

It’s possible that the perfect camper restoration project is around the corner from where you’re sitting right now. But more likely, finding a worthy candidate often leads to traveling thousands of miles to retrieve, such as the Boles Aero featured in this book.

Finding the proper bolt-pattern wheels for this camper would have been difficult. Just finding a good set of tires took a day to complete. While the wheels were off, the hubs were disassembled and re-greased to ensure that it would make the trip to Salt Lake City. It’s always fun disassembling stuff in a dirty environment. If it had been windy, the hubs would not have been serviced because dust would contaminate the bearings.

Trailer lights were run under the trailer and zip-tied to LP lines and frame wheels. Because there wasn’t anything ferrous to attach the magnetic trailer light kit to, they were duct-taped to the original light buckets.

The Ensenada was originally a park model, which means that there were no fresh, gray-, or black-water tanks installed on the camper. To make it usable off-grid, holding tanks were added to the unit.

The basic interior layout was retained, but a few changes were made to open up the interior and accommodate modern conveniences. Now a 12-volt electrical system based on two 6-volt glass-mat batteries powers interior electrical components, including lighting and ventilation. When plugged into shore power, the batteries are maintained, and the 110-volt outlets are powered.

This is how the Boles Aero looked when it arrived at Camper Reparadise. Water damage was pretty rampant, affecting the usual locations, including the vent opening and windows, and some not-too-common places such as the galley.

Some custom cabinetry from a previous owner had taken the place of the original liquid propane heater, but thankfully, the heater was found in a pile of scrap in an adjacent field.

The galley retained its original faucet and the cabinets still had their art deco latches, which are the important bits. Sourcing hardware that matches these originals can be difficult.

The name Boles Aero carries just as much history as an Airstream but is less of a household name due to the company closing its doors in the 1980s. They are a riveted, lightweight, all-aluminum top-quality trailer that dates back to the post–World War II trailer camper boom. According to Tincantourists.com, Don Boles, the Boles Aero founder, was instrumental in founding the consumer rally and show that by the mid-1960s was the largest RV-related event in the world.

Boles Aero contributed many design features still used today, such as flush vent covers, recessed fillers, and flush door handles for a smooth, aerodynamic profile. Not only that, Don Boles spearheaded setting industry standards for safety and quality that were enforced by various associations. It’s estimated that nearly 18,000 trailers of various types and configurations were produced by the Boles factory in Burbank, California. ■

Adding trailer lights to a vintage camper can be difficult because the light kits are designed to magnetically attach to bumpers. Many early campers, such as this Boles Aero, did not have bumpers. To get this trailer 800 miles home, the trailer lights were taped to the camper’s original light buckets.

A quilted stainless-steel backsplash, solid black-walnut countertops, and painted walls give this 1950s Boles Aero a classic yet distinctive look. It also hides many contemporary upgrades, including an LED TV in the galley cabinet (it pops up through the countertop when needed). (Photo Courtesy Joe Roberts, Abaci Photos)

The original restored heater adds to the Boles Aero’s history and interior space. A quilted heat shield ties this space into the galley, while the shoe storage by the door is a custom feature. The walnut ceiling and Marmoleum floor go the length of the trailer. In back is a full-size shower and queen-size bed. (Photo Courtesy Joe Roberts, Abaci Photos)

A TV is hidden in the galley countertop, and a modern water heater, range, and fridge ensure that these conveniences operate flawlessly. For the sound system, modern speakers are hidden behind original venting slats. The interior finish is a fresh change from the normal varnished birch common in most vintage campers. Painted walls and cabinets set off the walnut ceiling. Original, refinished cabinet hardware and fastening screws retain the vintage art deco feel.

The floor is finished with Marmoleum, and the walls are insulated with 2-pound closed-cell foam. The result is a vintage camper unlike any other and a great retreat after a long day.

Airstream Sovereign

The other camper that is featured in this book is a 1970s Airstream Sovereign. This restoration arrived as a blank canvas, with an owner ready to try something different. With the goal of off-grid capabilities and fully featured interior accoutrements, I set out to build something special.

As with most of my restorations, 2-pound closed-cell spray foam insulates this camper from the elements. After the exterior was patched and sealed, insulation was sprayed on the walls, ceiling, and belly pan to provide 360 degrees of thermal efficiency and sound deadening. The coach is warmed by an Aquahot system that also heats water for the sinks and shower.

When cabin heat is needed, the hot water is circulated throughout the cabin and fed through heat exchangers until the thermostat tells the system to stop circulating. The result is quiet and safe heat. The system can run on liquid propane or 120-volt electricity. To power the large Airstream off-grid, six 6-volt glass-mat batteries are charged by solar panels and an external generator.

If your wish is for a fully custom interior, you can often find someone else’s abandoned project for cheap. This Airstream arrived fully gutted and ready for a custom interior design.

Even though someone had already installed a new subfloor, it was removed to ensure that there was no rot and to add insulation and new tanks. The endcap, window surrounds, and interior skin still need to be removed.

A wood-burning stove in this Airstream provides heat and ambiance, a unique feature that you do not find on a production camper. Both the galley and bathroom are split into two sections. There are no overhead cabinets, which lends to the feel of an open space. (Photo Courtesy Joe Roberts, Abaci Photos)

Behind the art glass, a 43-inch TV is hidden and raises and lowers via a remote control. This is a clever way to hide an often-taboo item like a TV in a recreational vehicle. Vents at the front of the TV cabinet provide heat from the Aquahot system. (Photo Courtesy Joe Roberts, Abaci Photos)

The solid-surface counters in this Airstream are easy to clean and work well with their simplicity. The range is opposite of the sink to increase counter space. Instead of factory plastic knobs on the window levers, custom aluminum handles complement the marine window shades. Another custom feature is the walnut droplights above the countertops. (Photo Courtesy Joe Roberts, Abaci Photos)

The interior features custom walnut cabinetry, Marmoleum flooring, and new aluminum skin. The front endcap features back-mounted woofers for the sound system, while the tweeters are mounted above the front windows. For entertainment, a 43-inch TV is hidden inside the cabinet by the door. Art glass in the TV cabinet ties into the glass found at the end of the galley, which covers the audio system’s amplifier.

Art glass is also used for the shower and bathroom doors. This glass was crafted by a local artist for this project and is intended to represent Aspen trees. The green glass leaves also coordinate with the custom lounge upholstery.

The split galley (sink on one side, range on the other) houses two high-efficiency Engle refrigerators/freezers. Two are used to maximize space. Having two fridges is a common practice on land yachts, where efficiency and space is a priority.

On the sink side, a clothing washer and dryer are housed in the cabinet. This unit is for shore power or generator use only, like the low-profile Dometic A/C unit mounted on top of the Airstream.

The countertops are a solid surface and were produced by a local manufacturer.

Dual 12-volt fridges help to maximize space, while the drop-down counter and lounge area can do double-duty as a computer workstation. Across from the fridges, a washer/dryer all-in-one unit is hidden in the cabinet. (Photo Courtesy Joe Roberts, Abaci Photos)

The exterior was left as is to ease maintenance, rather than stripping the clear coat and polishing. On top of the coupler is the Aquahot water heating system and a propane tank. (Photo Courtesy Joe Roberts, Abaci Photos)

CHAPTER 1

GETTING STARTED

Restoration, a term used loosely in many fields, is defined as the act or process of returning something to its original condition by repairing it, cleaning it, etc. For vintage campers, returning one to a concours level or to museum quality might not fit your intent or purpose. But some of these campers are treasured pieces of Americana and should be treated as such. That said, retaining the essence of your vintage camper is just as important as making it more habitable than its current, unrestored state.

Because camper restoration involves many skills (from metal fabrication to carpentry to upholstery to paint), you need to focus on your strengths and arrange to outsource your weaknesses to skilled professionals for a quality end product.

In one circumstance, you might plan on a museum-piece restoration, where respecting originality and preserving as much as possible is paramount. In that case, cloth-covered wiring and retaining factory split rims are some of the details that are crucial to the camper’s originality. Unfortunately, they’re both often lost, understandably, in favor of safer, more modern alternatives.

In another circumstance, you might plan to bring the unit up to a usable state by replacing the axles and wheels with modern alternatives. Given the choices available, I like to divide restorations into three categories: the Usable Weekender, the Park Model (an off-grid cottage/rental/mother-In-law version), and the Show Camper (a museum/concours renovation).

The Usable Weekender restoration includes addressing all major systems to produce a vintage camper that can be towed to any destination and provide all the comforts expected of a camper.

A Park Model restoration is essentially building a unit that’s dependent on the grid (shore power, city water, and waste-water hook-ups) and not focused on stand-alone systems (12-volt/liquid propane).

A Show Camper restoration carefully retains all original components, materials, and building techniques of the era. And, in some instances, it avoids repainting or upsetting the originality of the unit, only preserving decay-prone materials.

You need to decide what priorities are essential to your goals and plan accordingly.

A Show Camper requires attention to detail and respecting the originality of a vintage camper. But this doesn’t mean you can’t make improvements to safety or usability without compromising the vintage essence of the camper.

Built in a similar manner to Airstream, this Boles Aero can be a less-expensive alternative due to less brand awareness. The downside is less parts availability. The challenge and reward of finding and creating working solutions makes the restoration process gratifying.

Models to Consider

While Airstream is a household name, many manufacturers from the heyday of interstate travel share general construction techniques. This book focuses on the riveted style of fabrication that’s favored for its low weight and structural integrity. The process is loosely based on airplane manufacturing and many of the tools are interchangeable.

Silver Streak, Barth, Avion, and Boles Aero, to name a few, all use aluminum ribs riveted to aluminum sheet metal; and, because they’re not branded with the Airstream name, prices can be more reasonable. At least half a dozen manufacturers share this construction method, and the techniques used in this book can be applied to many of them.

The downside to a non-Airstream riveted restoration is that these manufacturers have not received the aftermarket love that Airstream has. You may find it difficult to source some unique components for these trailers. But the challenge and reward of finding and creating working solutions is part of what makes the restoration process enjoyable.

Things to Avoid

When shopping for a project camper, there are some important things to avoid that make the restoration go smoother. For example, most aluminum campers of the 1950s and 1960s have panels with distinct patterning or curves that might be expensive to tool and re-create.

Trying to find a unit with endcaps and ornamental body panels in good shape should be a priority. Pretty much anything can be re-created by a metal fabrication specialist, but the cost to do so can easily blow a small budget. With this in mind, dented or creased panels, which are flat, are easier to repair or replace and can be used in your favor when negotiating a price.

As expected of a 60-year-old camper, there are a couple of red flags on this Flying Cloud worth noting. A dented corner panel might jump out, but it’s the least concerning. The extended coupler with suspect fabrication accompanied by a non-original curbside front window proved to be difficult to properly address but not an impossible task if you are resourceful.

This 1960s Tradewind is rough and dirty, much the same as the 1950 Flying Cloud. This is a much better candidate for a smooth restoration because it retains all the original windows, its panels are in great shape, and the chassis, including the coupler, seems to be much straighter. This unit does, however, have split rims, so an axle replacement and new tires and rims should be planned.

The interior finish of some panels in this Cruisette had army-green finishes, indicating that it was from the stock of surplus aluminum sourced by Wally Byam after World War II. When planning on panel replacement, you need to consider the difference between vintage aluminum and new stock. Current aluminum matrixes do not perfectly match vintage aluminum when polished.

Another thing to consider when assessing a candidate for restoration is replacing old aluminum paneling with new paneling. New aluminum isn’t the same as the original because the elements used in manufacturing (and suppliers) have changed since the production of the camper. If you’re going to replace a large curbside panel, the quality of the polish and finish of the new aluminum will not match that of the original pieces.

Although not a deal breaker for a Usable Weekender, the difference will be noticeable to a trained eye. In the case of post–World War II Airstreams, surplus military aluminum was used extensively and can often be identified by army-green finishes.

Missing emblems are another big hassle. The pot-metal dies are most likely long gone for most vintage campers, and finding the correct ones for your restoration will be difficult. These items define the camper, and while not impossible to reproduce or locate, it will be difficult and time-consuming. Try to find a unit with intact, or at least partially intact, branding (i.e., emblems and decals).

Appliances are another important factor. They do wear out and are often replaced with newer models or scrapped altogether. An original range and fridge or ice chest is important to the restoration process. If you can find a unit with factory-specified appliances, a show-quality or respectful restoration will go smoother. Or, it could dictate what kind of restoration path you’re going to take. If you’ve found an already-replaced or updated fridge and stove, you might go modern and skip the vintage appliances in favor of ease of use. Also, many recreation vehicle appliances are shared across manufacturers, which makes a tasteful, period-correct restoration possible.

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