78 Fleet Rebuild

[pods8]

I used 6063 too because that is what I could get in 1x1x.062 in bulk.

Looks like your welder came with a CK torch, I upgraded to one of those as well cause my original torch with the lincoln got hot after a while, that torch you can pound some amps in if you want to for longer. Did you get the longer 25' cord on the torch? I found that to be really nice when working around on the camper and not needing to move the welder.

Don't know if it helps or not but I put a stubby gas lens on mine, if anything I don't have to deal with as long of a cup.

Setting preferences take some messing around with but I've done most of my aluminum welds with a 1.3sec pulse, 120hz, 70% EN balance. Looks like your machine has more settings for up/down slope, gas flow and percentage of power in the pulse, those are all fixed on the lincoln so not as efficient with gas, etc.

A second gas tank doesn't hurt if you don't have one on hand, makes sure you don't run out during a project weekend or have to run to the supplier as often.

 

[Pac12_afterdark]

I used 6063 too because that is what I could get in 1x1x.062 in bulk.

Looks like your welder came with a CK torch, I upgraded to one of those as well cause my original torch with the lincoln got hot after a while, that torch you can pound some amps in if you want to for longer. Did you get the longer 25' cord on the torch? I found that to be really nice when working around on the camper and not needing to move the welder.

Don't know if it helps or not but I put a stubby gas lens on mine, if anything I don't have to deal with as long of a cup.

Setting preferences take some messing around with but I've done most of my aluminum welds with a 1.3sec pulse, 120hz, 70% EN balance. Looks like your machine has more settings for up/down slope, gas flow and percentage of power in the pulse, those are all fixed on the lincoln so not as efficient with gas, etc.

A second gas tank doesn't hurt if you don't have one on hand, makes sure you don't run out during a project weekend or have to run to the supplier as often.

That’s great advice, now I’m worried. I got .125” wall. I should have measured! Doh! Guess I’ll do some practice welds to find settings that penetrate the .125 and don’t blow out the .063.


I’ll pick up one of those kits! Lots of people talking about them on YouTube being superior. I did spring for the 25’ torch. Basically a “free” upgrade with the Black Friday deal.

How long of a post weld gas flow were you using? I agree in a second tank, humphries has been a good gas vendor on this one. I am still working on understanding all the setting, but need to understand how much “common cause” variation I have in my welding before messing with settings.

 

[Pac12_afterdark]

Quick trim question if one of you know. It seems like fwc no longer uses the “insert” style trim from these photos.

Can anyone confirm? I was planning on running black trim with insert which is what my camper had on it. I’d think what they are using now is basically angle aluminum which I would think is a substantial savings. I also attached the “old” style trim. Anyone know why they switched?

Thanks all!

 

[pods8]

How long of a post weld gas flow were you using? I agree in a second tank, humphries has been a good gas vendor on this one. I am still working on understanding all the setting, but need to understand how much “common cause” variation I have in my welding before messing with settings.

Post flow is a fixed rate on the Lincoln and much longer than needed. Being you can adjust yours maybe try around 5sec and pay attention to how long the gas is still flowing after the pool has cooled. The aluminum solidifies fairly quick so I don't think all the much is needed.

Quick trim question if one of you know. It seems like fwc no longer uses the “insert” style trim from these photos.

Can anyone confirm? I was planning on running black trim with insert which is what my camper had on it. I’d think what they are using now is basically angle aluminum which I would think is a substantial savings. I also attached the “old” style trim. Anyone know why they switched?

I was noticing the same thing and weighing out pros/cons. The insert trim does offer some weather shield on the screws but a properly sealed screw doesn't need it either.

 

[Pac12_afterdark]

Post flow is a fixed rate on the Lincoln and much longer than needed. Being you can adjust yours maybe try around 5sec and pay attention to how long the gas is still flowing after the pool has cooled. The aluminum solidifies fairly quick so I don't think all the much is needed.

I was noticing the same thing and weighing out pros/cons. The insert trim does offer some weather shield on the screws but a properly sealed screw doesn't need it either.

Which one did you end up going with?

 

[Pac12_afterdark]

Started on the front end today. That .125 takes a ton of heat to get a puddle going. Also cut off the diving board on the front.

 

[pods8]

Which one did you end up going with?

Haven't reached that Y in the road yet. Just flipped my frame over from installing and painting the wood floorpack.

 

[Pac12_afterdark]

finished the front and back today. The freaking floor pack gave out wholeness building and the whole thing came crashing down. So I got to rebuild the front all over again.

Always, overcame adversity.

Got the big back end welded in for the larger flip up style door I plan on doing.

If anyone is reading this in the future take off the top when doing a total rebuild. Totally ruins the MOI.

Onward we go, floor pack is next.

 

[Pac12_afterdark]

Thursday or so I’ll rip the old floor pack out and start on rebuilding that portion.

 

[Pac12_afterdark]

Haven't reached that Y in the road yet. Just flipped my frame over from installing and painting the wood floorpack.

Which paint did you use?

 

[pods8]

Which paint did you use?

I went way overkill because I had leftover supplies from a prior composite build attempt. So I did a layer of epoxy/fiberglass on the exterior, then epoxy primer and then a two part urethane bedliner.

The interior I won’t glass but I’ll skim coat in epoxy and then use the same coating to use up what I have already. It won’t be rotting away anytime soon lol.

 

[Pac12_afterdark]

I went way overkill because I had leftover supplies from a prior composite build attempt. So I did a layer of epoxy/fiberglass on the exterior, then epoxy primer and then a two part urethane bedliner.

The interior I won’t glass but I’ll skim coat in epoxy and then use the same coating to use up what I have already. It won’t be rotting away anytime soon lol.

Man what a proper install though! I love the stringers. I rebuilt a drift boat a few years ago and I’m not ready to go back to fiberglass just yet.

Got my the frame finished yesterday. The side window mocked up. I’m going to move it up one inch today though.

Also gone everything measured out for the floor pack. Not sure if I’ll get started on it today or not we’ll see how ambitious I am.

 

[Pac12_afterdark]

Successful day!

 

[Pac12_afterdark]

Mocked up all the accessories on the drivers side while I wait for deliveries. Almost time to get into siding.

 

[Pac12_afterdark]

Not too much progress today. Sanding the exterior floor pack and prepping it for bed liner.

Also got all my deliveries so tomorrow I’ll pick up a nibbler and start getting sides on!

 

[Pac12_afterdark]

Seams caulked and Berliner (1st coat) on. Saw mixed reviews on if it holds up, but couldn’t find any exact info on pressure treated ply. I’ll report here if it holds up I guess! The exposure and fiberglass would of been the best option, but I wasn’t willing to let the scope creep that far.

 

[Pac12_afterdark]

Everything fabricated in, next step siding. I might move the front window down a bit.

 

[Pac12_afterdark]

Got all my panels cut and in. Now I need to decide on trim, read up on sealing properly and finish up some other things.

I love the way it’s looking. The wind took away the aluminum so there are some creases unfortunately.

 

[Vic Harder]

nice. I note the two piece front. Never seen that on a FWC/ATC.

 

[Pac12_afterdark]

nice. I note the two piece front. Never seen that on a FWC/ATC.

That was what it had when I tore it down. I don’t love it, but with 48” roll of siding it’s all I could do really!

My plan is to run a flat piece of trim across it to tie it together, and recess that into the 3” poly bumpers up there to try and make it look more seamless.

I might have enough siding left over to make one run across it but it will be close. I’ll have to see what I have left when I finish the back door.