American Clipper Owners Club

Tips & Tricks => House Remodeling => Topic started by: JerryT on December 10, 2007, 10:39:07 AM

Title: Big hole in roof over bunk!
Post by: JerryT on December 10, 2007, 10:39:07 AM
Hi All
I haven't posted in a while but I have been planning my winter Clipper improvement's. I am hopeful that I will get it all done including a paint job but it is a big list. I am going to try and post with pics at least once a week things that I am doing and things all ready done. One thing I am doing is cutting a 5'X6' hole in the roof over the bunk to allow for more head room. I have bought a Nose Cone to cover the hole. A Nose Cone is a fiberglass air deflector that is used on the front of semi trailers, it kinda looks like a big pillow. It is aerodynamic in shape (If it matters :)) and will add about 6" to the height over the a/c unit. It adds about 14" to the bunk in the center so you can sit up straight. Here is a few pics of the work so far I will post more later.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: JerryT on December 10, 2007, 11:07:28 AM
more pics
Title: Re: Big hole in roof over bunk!
Post by: Shayne on December 15, 2007, 11:33:36 PM
Wow, now that's bravery right there :D  Cutting a hole that big in the roof takes some guts. ;)

Good luck with your project!
Title: Re: Big hole in roof over bunk!
Post by: JerryT on December 16, 2007, 08:09:41 AM
Thanks Shayne!
Guts or stupidity :D either way this is going to be a nice improvement, I know I will use the bunk a lot more, just being able to sit up adds so much. The upshot, it's going to be one of the easier major things I have done to the Clipper so far. I wasn't sure of what it would entail before I cut the hole, but it is getting easy. I think I will have 5 work hours max installing the nose cone on the top. I am guessing it will take longer to glue the insulation and headliner in place and the headliner material will self trim the job, it's really going to be slick. This thing's hard to photograph on the inside but here are a few.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: JerryT on December 22, 2007, 08:01:13 PM
Hi All!
Work is going well on getting Fillmore ready to paint. Lots of little repairs and tucking up as I like to call it. One change I decided to make was to the left overhead bunk window. The Clipper uses all right side window cranks but I felt that the left bunk window should be a left side crank so I could reach it from a standing position instead of crawling into the bunk. I noticed that you could buy the gear box for left or right side, and upon inspecting the window I found thar all parts could be switched from side to side and the screen fliped over (spline out). So for 30 minutes work and four pop rivets I reversed the operator from right to left. I took a few pics to share. Note, I chose to open my gear box and flip over the drive collar instead of buying a new one.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: JerryT on December 22, 2007, 08:12:55 PM
Here's more pics of the switch. I found a company called Pelland Ent. !-800-216-2786 and/or <pellandent.com> I called them and was told they have all parts for our Hehr windows and they do show some parts on their web site. I want to replace the rubber seals but may wait post paint job (summer) to tear into it.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: Horst on December 29, 2007, 06:43:48 AM
Jerry,
This is simply an awesome mod.
But - no more escape hatch out the top I suppose?
Still - very cool - wish I had a shop like yours!
I'm sitting here in my Clipper typing this note - wireless access
to our house - with wife and kids sleeping in the Clipper!
We "camped" in the front yard - the family misses going on trips
so this is how we compensate - still having fun - it puts us all in close quarters.

You are inspiring me to make one more additional mod that I have been
putting off for years - creating a bunkbed above our couch (behind the passengers seat)
I have seen it done once - someone took
the backrest of the couch and had it swivel up and then attach to the ceiling - pretty slick
- and - he didn't have to remove the cabinets - but both sleeping berths were tight.
I was going to remove the cabinets to create a comfy sleeping bunk that will fit an adult.
But, I had some engineering obstacles  - so I sort of gave up on the idea.
But seeing you cut the top off your Clipper!!!! has given me a new psych!!
thanks
Horst
Title: Re: Big hole in roof over bunk!
Post by: JerryT on December 29, 2007, 05:33:44 PM
Thanks Horst!
Time, money and a place to do it is all a guy needs. It's winter up here so I got the time, money, well you know you find it when it's something you really want to do, and a place to do it, well it's my buddys shop and he's giving me a big gift in letting me work there, but we do trade favors back and forth but I now owe him big time :) Yes the escape hatch is gone. I thought about re-installing it but I don't think I could have climbed out of it being chest high instead of butt high. I think I will go with a nice roof fan instead. My coach had the rear ladder removed years ago which allows me a rear window awning, so for roof access I am going to carry a folding ladder across the back in a 6" mat tube I have planned. We have camped many a night at the ROXNJER campground at home base, complete with wifi internet access, semi full hookup's and honey do views :) I like your bunk idea but I could not give up my overhead cabinets. How about a pup tent and a short straw? I have put door/drawer slides under my couch bottom so it will slide out a few more inches so you can relax/sleep on it and then slide it back in when your done. I could only get about 1 1/2 cheeks and one elbow on mine in stock form. Now it even slides in further as to allow the fridge door to open all the way, more isle room too. It can still be used as a dbl. bed also. I will try and post some pics of the mod. soon. We are preping for paint right now, here are some pics.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: JerryT on December 30, 2007, 02:15:08 PM
Hi All
I've thought about reversing the swing on the back door so as to enjoy the awning/patio area more. This summer (07) we were invited to camp at the Coachman 40th anv. campfest in Centerville Michigan They had installed on the top of their doors  a lift type strut rod that either kept the door open or closed. I knew that was the key to my door change as I didn't want the door to pop open going down the road and I liked the idea of the door staying open without a bungee cord, lame grip fastner or whatever. So I am going to flip the door over and do what it takes to make this all work, should be eaiser than my roof project :) Here are a few pics of the Coachman doors and of mine.
P.S. this is how they lit the charcoal for the free burgers.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: JerryT on January 05, 2008, 05:50:28 AM
Here are more door pics, I hope this makes you smile!
JerryT
Title: Re: Big hole in roof over bunk!
Post by: JerryT on January 06, 2008, 10:18:05 PM
Hi all
I knew the bottom of my door was a bit soft and knew it would need repair when I reversed the swing so today I opened her up for a look see. Here are some pics.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: JerryT on January 06, 2008, 10:19:20 PM
more pics
Title: Re: Big hole in roof over bunk!
Post by: JerryT on January 06, 2008, 10:21:34 PM
Still more pics!
Title: Re: Big hole in roof over bunk!
Post by: JerryT on January 06, 2008, 10:23:40 PM
and a few more
Title: Re: Big hole in roof over bunk!
Post by: JerryT on February 24, 2008, 07:22:36 PM
Hi All
Works going well on Fillmore, we are about at the paint it stage, we have the door jams and inside doors painted as well as under the hood and many misc parts. I have some more pics to post as well as some advise, NEVER SAND BLAST with your new camera in your top pocket >:( makes funny crunchy noise and quits working, but I did get the pics down loaded first. We sent it in for repair but still not back. Here are some progress shots starting with rebuilding the door. NEXT PICS ON PAGE 2 sorry this is getting long.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: JerryT on February 24, 2008, 07:26:12 PM
And a few more
Title: Re: Big hole in roof over bunk!
Post by: JerryT on February 24, 2008, 07:36:13 PM
I was able to use the roof cut out for my new door skin, Sometines you just get lucky!  Last pic is of the scrap, not much maybe 1/2"
Title: Re: Big hole in roof over bunk!
Post by: JerryT on February 24, 2008, 07:44:00 PM
We had to de-laminate the roof fiberglass from the wood backing, also the roof was thicker than the old door by 50% Pic 4 is the wood backing, some kind of end cut glued up deal, I have never seen this used in anything before.
Title: Re: Big hole in roof over bunk!
Post by: JerryT on February 24, 2008, 07:53:21 PM
Next a new skin for the inside. I had some wood grain vinyl covered almond colored soffit material left over from a house project so the price was right ;D and now with the door open the color matches the outside color of the coach and it is behind the screen when the door is closed so win/win/win.
Title: Re: Big hole in roof over bunk!
Post by: JerryT on February 24, 2008, 08:00:30 PM
Here we get to test fit it with the reversed swing. this door project has been a bigger job than installing the nose cone(dome).
Title: Re: Big hole in roof over bunk!
Post by: JerryT on February 24, 2008, 08:07:32 PM
Now we get to play with the door operer/closer, it works great! No more whimpy door grip/bungee cord PITA deal. It keeps the door open and also keeps the door closed :D
Title: Re: Big hole in roof over bunk!
Post by: JerryT on February 24, 2008, 08:27:36 PM
I saved the crate the nose cone came in and we used it alot. It made a good work platform, it was perfect while I was "weighting" for the glue to dry ;), I wonder if I could ? NO I better not, well I'll just think about it :-\
Title: Re: Big hole in roof over bunk!
Post by: JerryT on February 24, 2008, 08:30:52 PM
More crate ideas
Title: Re: Big hole in roof over bunk!
Post by: JerryT on February 24, 2008, 08:38:33 PM
My sister and her hubby are semi truck drivers so here is a pic of my Christmas present, I don't know if I want to use them or not? Also working on a motorhome is nice because you have a kitchen for snacks, well one day the fridge started to loose its cool and kept getting worse, it is the orig so I thought it may be time for a new one. I kept turning up the stat but still no cool-- then I figured it out, pic 2&3
Thats all for now.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: jon on March 02, 2008, 11:04:36 AM
I just might try your nose cone idea. As far as the escape hatch goes, I would never fit through that little hole anyway.   
Title: Re: Big hole in roof over bunk!
Post by: JerryT on March 05, 2008, 07:10:37 PM
Jon
I think it's a good trade, a little hole for a big bunk! It's so nice to sit up straight, the bunk feels like a new room, one that you want to spend time in. As a bonus, I ended up with a 12" shelf across the back (old roof) between the 4' ceiling joint and the rear of the nose cone just above the two bunk lights, see pics. If you really do put one on I will give you all the help I can. I just want to say again, this install was eaiser than I thought or even hoped!
JerryT 
Title: Re: Big hole in roof over bunk!
Post by: JerryT on March 08, 2008, 06:18:08 PM
Hi All!
I now have the dome glued down and the top of the Clipper painted ;D Here are some pics of the progress. I used 3M 5200 and gasketed hex head polebarn screws to hold it on and sealed it inside and out.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: JerryT on March 08, 2008, 06:20:07 PM
And some more
Jerryt
Title: Re: Big hole in roof over bunk!
Post by: JerryT on March 08, 2008, 07:08:39 PM
Here are some progress shots of the painting in various stages.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: JerryT on March 08, 2008, 07:20:04 PM
 I was going to paint the Clipper a new color that Chrysler has out called (Cool Vanilla) but when I matched it to the motorhome I found out that it is the same color as our old rigs, yep thats right Chrysler recycled an old color (eggshell) and gave it a new name Cool Vanilla!
JerryT
Title: Re: Big hole in roof over bunk!
Post by: rjm on April 30, 2008, 07:31:23 PM
Nice Job :)

just curious, did you have any luck finding the codes for the brown and orange?

or did I just miss the text while I was scrolling through the pictures ;D

I have a bunch of drivetrain work to do on my 76, but once thats done and exterior upgrade might be a good idea.

tks,
rjm

Title: Re: Big hole in roof over bunk!
Post by: JerryT on May 12, 2008, 07:04:35 PM
When I started out to paint mine I planed to re stripe it, but now I am starting to like it plain (cool vanilla) I am leaning toward some pin stripes as I am enjoying all the feature lines and styling that it has. I saw the paint codes in an old Clipper newsletter, I'll try to find them and post it.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: clockwork on May 17, 2008, 07:11:27 AM
I like the plain cool vanilla- it's not flashy, but kinda' goes along with (what I believe was ) Irv's  philosophy for the AC:  Keep it simple, Keep it quality, and you'll be able to keep it for a long time.

dave   
Title: Re: Big hole in roof over bunk!
Post by: JerryT on May 22, 2008, 06:56:55 AM
Hi All
Finally have some time to post a few pics and info. I got the Clipper back on the road and have taken a 2100 mile trip so far, and weeding a few more bugs out (it never ends :)) I have not finished the inside of the dome yet, still playing catch-up on all that got ignored while I (played says the wife) worked on the camper. Don't see many Clippers east of the Mississippi but I did see two, I got pics of the first one, it was # 2524, a 75-76 I think. The other one was a ways off the road in the front yard of a person that seemed to own a lot of things and had them all out for everyone to see, but I bet none of it was for sale so I didn't stop. Other than painting, I did four main things to make the Clipper more accommodating for us. #1 the roof dome over the bunk, #2 a roof storage pod behind the dome, #3 I reversed the swing of the coach door, #4 I installed a storage tube above the back bumper that I use for the patio mat and folding ladder, ect. I also had to get a new set of tires as the old ones were about to fail, I knew they were getting old and I was keeping an eye on them but did not know how bad they were untill I had them off in the shop. I put on a set of  Firestone Transforce 16.5's They cost me $117.00 each and I mounted them my self. They are a nice tire and the Clipper drives better and is much quieter now. Here are some pics.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: JerryT on May 30, 2008, 03:16:17 PM
more pics
Title: Re: Big hole in roof over bunk!
Post by: ClipperFan on July 02, 2008, 05:48:00 PM
glad to see others remodeling clippers!!  Can you post pics of your clipper after you painted it with the dome on?  These pics dont look like yours are they?
Title: Re: Big hole in roof over bunk!
Post by: JerryT on July 05, 2008, 09:24:36 AM
ClipperFan,
The Clipper on the left with the bikes is mine, but your right I have not posted any finished pics yet!
Camera died, then laptop died, now I am on vacation again camping on the shores of lake Superior in the upper P of Michigan. Will post a few late this week when we get home. FYI, I love the dome and the reversed door!! Also I was able to fit a 31 series Trojan deep cycle battery in the house battery bay, we have dry camped for a week and have not run out of power. We have been out three times for a total of 40 days, it's been like a dream, everything works perfectly, I feel like I am in a new $100,000.00 rig.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: jon on July 16, 2008, 04:23:22 PM
Brand new 16.5 tires...OUCH expensive. I plan on scouring the Junk yards this winter for 16 in wheels that fit. I think I found some laying in my mother inlaws barn 200 miles away but I wont say anything till I go get them and try to put them on.
Title: Re: Big hole in roof over bunk!
Post by: JerryT on March 26, 2009, 06:27:16 PM
Hi all
Finally got the interior in the dome done last fall. I used 3/4" thick black neoprene for the insulation and a product called superflex for the cloth headliner. I glued the foam directly to the inside of the dome first and then the superflex was installed to the foam. I ordered the foam pre-glued (peel-n-stick) on one side (down) to make attaching the cloth easier. The superflex is made like steel wool, you can stretch it a lot, good for odd shapes. We duct taped the seams (for you duct tape fans) :D so they would not show. Here are a few pics.
JerryT 
Title: Re: Big hole in roof over bunk!
Post by: JerryT on March 26, 2009, 06:29:08 PM
And a couple more.
Title: Re: Big hole in roof over bunk!
Post by: JerryT on December 05, 2009, 05:46:02 PM
Hi Don, look at the pics and I will answer any questions you have.
JerryT
Title: Re: Big hole in roof over bunk!
Post by: JerryT on March 03, 2010, 07:27:34 PM
Here are a couple pics of the "finished" project, it's never finished ::)
JerryT
Title: Re: Big hole in roof over bunk!
Post by: Horst on March 03, 2010, 09:00:16 PM
Nice grille!   ;)
Title: Re: Big hole in roof over bunk!
Post by: JerryT on March 05, 2010, 06:58:01 PM
Hi Horst
The early aluminum grill is my favorite ;D I was at a swap meet and I saw an early grill that was chrome plated steel. I had never saw a chromed one before. I have seen painted white ones. I looked at it 3 or 4 times but decided I like the finish of the aluminum one better.
JerryT 
Title: Re: Big hole in roof over bunk!
Post by: Horst on March 08, 2010, 07:45:16 PM
yep - I switched mine a few years back - I just don't like the plastic ones - the vintage ones look better - and fit perfect
Title: Re: Big hole in roof over bunk!
Post by: cpcarroll on March 08, 2010, 07:58:58 PM
Horst
What years are the vintage grills from that will fit a 1978?

Thanks Chuck
Title: Re: Big hole in roof over bunk!
Post by: JerryT on March 11, 2010, 05:47:48 AM
Hi Chuck
I think 71 to 73 are the early grills, anybody else?

JerryT
Title: Re: Big hole in roof over bunk!
Post by: Horst on March 26, 2010, 11:13:30 AM
I'm not 100% sure here - but I think, like Jerry said - they were made from 71 to 73 (maybe 70 as well??) - anyway, they do fit my 75, and I'm quite sure a 76 as well - not totally sure about other years - but my guess is no problem - (except maybe for 1980)- there are two or three screw holes that didn'tt match up - but no worries - the other 8 to 10 hold it in place fine - most importantly, the ones around the headlight matched up perfectly (on mine at least)

have you found one somewhere?
Title: Re: Big hole in roof over bunk!
Post by: John Eversoll on March 27, 2010, 01:24:36 AM

Hey Buddy, how ya doin...

Ya know I had the hardest time finding a grill for my 77....

Fact is I bought three before I had one that would fit right..

One broke after I put in the last screw... It seems like they are not bent "formed the same way...
I matched them up and the 77 has more of a bend in the center...

I used a grinder and ground out some of the inercenter to compensate

It did seem to work. Well tomorro I be putting in the newer seats.

Then moving on to get rid of that fridge.  Like I told ya, I bought the electric fridge

for $165. it is taller and deeper ot as wide so I will have to build a cabinet for more food storage.   Got to load up on that Spam!!!  Love that stuff...We should be leaving for oREGON THE SECOND WEEK IN August ..  sorry about the Caps...

Will try to hook up with Carrol one we get up there....
Take care,  John
Title: Re: Big hole in roof over bunk!
Post by: JerryT on January 09, 2011, 10:04:52 AM
Bump
Title: Re: Big hole in roof over bunk!
Post by: USNRetired on January 11, 2011, 06:16:56 PM
JerryT, You know you've done a terrible thing, don't you?  Now I'm going to have to install one of these thayngs in my '77 Clipper.   I'll have to wait until summer, so I can do it in my RV storage lot.  Cutting the hole and installing the nose over the hole should go pretty fast (I hope).  But it sounds like one heck of a project!  But from what I see of the Photographic results, the results are fantastic.
Title: Re: Big hole in roof over bunk!
Post by: JerryT on January 12, 2011, 04:59:13 PM
Thanks Jim!
Yes, it goes on quick for the size of the project. I spent more time trimming the inside than I did outside. I used mine all summer untrimmed, just so happy to have the room. With the vent on top it did not get hot inside. I added 3/4 neoprene foam insulation to the dome, might have used 1/2 if I did it over again. The insulation did not seem to make as big of a difference as I thought it would. I tell people I got the Motorhome at a NASA auction ::)

JerryT
Title: Re: Big hole in roof over bunk!
Post by: Toedtoes on October 28, 2013, 10:00:29 PM
topping for SFine
Title: Re: Big hole in roof over bunk!
Post by: JerryT on October 16, 2017, 06:43:34 PM
Hi All---Jerry T here---Just wanted to say hi and mention how much we like the dome I installed on our Clipper. Had I not put it on we would have found a different coach, all caused by buying a thicker and very comfortable mattress. We use our Clipper all the time and get asked frequently ---what is it---who made it---where can I buy one. The smaller coaches seem to be in vogue right now and I am glad I have ours, truly a quality rig.
Title: Re: Big hole in roof over bunk!
Post by: Toedtoes on October 17, 2017, 08:55:14 AM
Welcome back JerryT!   Please let us know more about what's going on with your clipper.