End Cap Panels - Dent Be Gone!

When we first looked at buying an Airstream, we were offered a small discount on a new trailer with a basketball sized dent in the rear drivers-side end cap panels.  The dealer had backed into a tree branch when parking at the RV show at their fairgrounds.   Not knowing the work involved with end cap replacements we wisely passed on that opportunity.  Whew!  Good decision for us.

Two years later, we decided that our ideal vintage Airstream trailer was a 22 foot 1955 Flying Cloud.  One year after that we found our vintage Flying Cloud...perfect with a twin bed layout...and a basketball sized dent in the rear drivers-side end cap panel.  Guess that we were meant to buy a dented Airstream.

Now that has all changed.  Colin tried to remove the dent but the aluminum was stretched and could not be reformed.  As we were doing a full restoration with the interior skins removed, it was decided to replace the panels...One of those one time events in our lives, so "do it right" things.

With beads rolled at the bottom of our two new end panels, the panels were fitted with clecos before being buck riveted into place.

The final window frame was also buck riveted to the shell and end cap seam.

Colin's New Hobby - Beading

Colin added new equipment to his shop and just in time!  1955 Airstreams, actually "all" of the Airstreams until approximately 1959 were made with 13 panel end caps.  These thirteen end cap panels each has a rolled edge at the bottom of the aluminum which is made with a set of bead rollers.

Our 2008 CCD Airstream does not have this feature.  Don't run your fingers over these sharper seams!

Whale Tail Removed - Too Much - Creased, Stretched and Dented

We tried to save the original end cap panels.  Really tried.
The big dent is too big.  Too deep.  Too creased.












Permanently creased, the dented aluminum panels of the street-side end cap are again removed for replacement patterns.

Okay, here's the thing. I am not the handy one in the family. So as well as learning lots - my job is to document the process. So if anyone has any suggestions for how to improve this vintage Airstream blog, please do share with me using the comments feature below. Seriously, I'd like to think that I am not the only one reading this....

Big Dent - Big New Plans

When we bought our Airstream, the beautiful whale tail was dented - two of the end cap panels were dented.  Sadly deeply dented. And while not likely, I was truly wanting our dents to be removed, to be another vintage Airstream success story.

Colin Hyde Trailer Restorations has been successful removing dents, with deeper dents improved by 90% or more, so my decision was easy to make to save the panels.  The street-side end panels were removed.

Using their very best effort, and finessing the aluminum back into shape, the panels were attached with clecos back to our Airstream whale tale.  The panels are were dented, creased, and stretched.  The English wheel was not successful in removing the dent and the polished panels would be forever scarred.

So we made another easy decision that new panels will need to be fabricated and installed.

Preparation for Zolatone! Walls, Overhead Cabinets, and End Caps

To remove the old paint, old Zolatone, and prepare for the new Zolatone, the interior aluminum skin is sanded.

And more old paint is removed using chemical stripper.

Paint was removed from the overhead cabinets.

Overhead cabinets are ready to paint.

The front end cap paint being removed.  The wall sconce will re-use the hole.

This rear whale tail end cap panel will be replaced due to the street side originally poorly located electrical outlet.