~ The Floor Repair ~

Now We Are Into the Fun Stuff! Time to Start Fixing Things!

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"Obstacles Are What You See When You Take Your Eyes Off The Goal"

Have you ever wondered how these things are built? C'mon! I'll show you, roll up your sleeves, let's go!

One thing I need you to remember with this project. If it appears that some pics seem out of sync, or that you notice there is a repaired wall already but we are only starting the floor, it is because I did the repair out of order, but I am trying to organize it in some logical progression here.

You see, when I started, I thought it was fix the roof, patch the floor, good to go.... I was so wrong. I actually did a partial roof repair first. It wasn't until after I got into repairing the bathroom floor that I found more and more rot, I literally had the back of the floor fixed before I made the decision to dig deeper. The deeper I dug, the more I found and off I went into a rebuild I never intended to do when I first started. So yeah, there is some illogical order to it.

Click on Images to Enlarge

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Overview of corner:

Most of the bad wood is stripped out now. I had to use a broom and dustpan more than a hammer and prybar. It was rotted to nothing.

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Replacement Starts:

The back and one side up to the wheel well outside framework - replaced with clear fir for strength. This is the only place I used fir. This is the point where I realized that if I used this wood throughout, it would substantially add weight to the unit. From here to the end I used all KD spruce.

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Outside Framing Done:

Back and side up to wheel well replaced. You can see where the rest was reduced to pulp. I removed it with a broom and a dustpan.

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Framing Rotted to Nothing:

Those rotten pieces there are all that was left. They were rotted so bad I could step on them and crush them to pulp. Certainly no structure left there.

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Bathroom Joists:

Most of the joists are now replaced. It was necessary to butt-join them, so I had to add splice pieces to each side. Yes, that's my size 12 in the picture!

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Front of Bathroom:

Framing partly done. The intention was to stop here, so some joists were spliced.

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Back End Framing Done:

Joists all rebuilt now. Looks like I used clear fir there too. I started with that but stopped for the rest of it once I considered the extra weight I was adding. KD spruce was used on all the rest of the framing throughout.

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Bathroom Floor Framework:

All the structural members are now replaced. The bathroom floor is solid again. Heat ducts have been re-installed as well. Also note the tail light wiring on the left. Important to remember to run  these things while it's open.

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Bathroom Floor Framing:

Duplicated as original, all framing members are glued and screwed together. Black and grey tank pipes there

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Insulated Bathroom Floor:

If I'm going to add insulation, may as well do it right and fill the joist cavity. Ready for plywood now.

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Marking the Centers:

I wrote all the measurements on the outside so I would know where to run the screws. Look close at the rear.

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Tail Light Wiring:

I re-used the original wiring, it was OK. I put it on top of the insulation and ran it out in place to run it up the back wall.

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Notes On The Floor:

Throughout the whole project, I marked everything so I knew where the framing was once the plywood was on.

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Floor Sheeted:

Finally! New plywood down on the floor. Sure is a lot more solid now. Feels good to see some progress.

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Bathroom Floor Sheeted:

Another shot of the floor. I cut the black and grey tank pipes just above the floor. Easy to splice into them later on.

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Clear The Way!:

Gutted the thing. No turning back now. It is time to get serious about the project and really get after it. 

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Front Floor Area:

Well, I guess gutting it was the best way to go. Its the only way to fix it right. Most of the plywood is out now.

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Hollow Shell:

All cabinets and everything is out now. Now I have a clear space to work. Much easier with nothing in the way. Back wall is the access point for large items.

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Converter:

Through all this, I am still hooked up to shore power and it is still functioning! I have to be careful, but I am using many coach lights and all the 110V plugs.

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Replacing More Perimeter Framing:

Got the wall jacked up via the wheel well so I can replace the front structural members. Sure was no picnic getting all those screws out.

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Front Framework Replaced:

All the joists have been repaired now. I still think I should push it into the street and burn it!! This is too much work!

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Another View:

Note the wiring on the floor. This goes right to the back for the tail lights. All framing glued and screwed together.

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Curb Side Framing:

That pan there is where the furnace blows into the ducts for distribution. Just a bit of cleanup left to do here.

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Bare Floor Ready:

Looks white but that is actually the galvanized sheet underbelly skin. Now ready to insulate the rest of the floor

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Ready For Insulation Now:

I left the factory wimpy insulation sheet in place. It was undamaged there. I'll insulate over top of it for added R value.

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Similar View:

That insulation on the wall is the fridge vent. I had to plug air leaks where I could, as I had a heater in there to work.

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7 Pin Connector:

The cable there comes directly from the 7 pin. That mess is where it joins to the inside wiring for distribution. The trailer brakes wiring goes out through the floor halfway back.

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Ready For Plywood:

Many long hours went into this area. All insulated now and the covering for the furnace ducts has been replaced. Additional wiring for 12V plugs has been
run. I also ran a wire to the back for backup lights.

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Junk Storage:

Old pieces tended to get set back at the "other end" for now. Brown panels on left are the old duct covers. I replaced them all with .032 aluminum sheet I got for free, lightly damaged but who cares? It will all be covered with plywood.

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Ready For Plywood:

That coil of wire is for adding some 12V outlets to power various things. I also wired it for internet.

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Ready For Plywood:

All nicely insulated now. 2X3 joists. I split batts of R-20 in half for this. This gives me R-10 for the floor.

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Kitchen Area:

Looking at all that nice new insulation gives me a warm feeling of satisfaction. Yeah OK, that was pretty bad, I know..

A thought worth remembering. It is critical that the floor plywood be continuous from one side to the other. It is needed for strength. I lifted the walls up off the floor in order to put the plywood in from outside to outside. The trailer is exactly 8' wide, the width a full sheet of plywood. The plywood is glued and screwed to the joists. Good luck ever taking it apart!!

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New Plywood Finally Down:

Solid floor at last....... WHEW! ! That was one heckuva pile of work!

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The Only Original Floor:

This was the only piece that was not rotten. Just have to clean it up a bit.

OK, hold that thought. Remember the above caption the only original floor. Don't forget now, you haven't heard the last of this...... Stay tuned!

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New Plywood Down:

View from back of trailer. No more walking on the joists! I can walk on it easily now.

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Bolting The Floor Down:

First thing, move the wall over out of the way. Then drill a 5/16" hole up through the frame outrigger through the floor.

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Bolting The Floor Down:

5/16" Carriage bolt. In the hole and hammer it down until the top of the head is flush with the floor.

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Bolting The Floor Down:

Lockwasher and nut. Tighten it up very snugly making sure the top of the head is exactly flush with the floor. No more.

Alrighty! There's how you repair a floor properly. It is very important for the overall structure that the floor plywood be continuous from one side to the other, including under the walls. Not so easy to achieve without some serious dismantling. I literally disconnected all the walls all the way around and lifted the body of the trailer up off the floor in order to get the new floor sheeting in. I am a stickler for doing things right!

There you have it, a nice new solid floor, sheeted with tongue and groove 5/8 select plywood.

Now that we have something solid to work on, lets get into the walls and see how they look.

Are you ready?