1988 Jayco Jay class C cabover rebuild.

[Todd]

The beloved class c came to my family in early spring with the knowledge that it would need some attention but what came as a surprise to us was just how much attention it would need.

 

My friend's dad had previously owned the RV for 14 years in which it was mostly a yard orniment.

As I pulled out of their driveway I looked at the milage on the odometer and the milage on the title. It had been driven 497 miles in 14 years!!!

I did an oil change, replaced tires, new fuel filter, belts, sparkplugs ect. ect. Typical things that needed attention to make it safe to drive. 

 

And drive we did!!!

My 12 year old son races motorcycles which is usually about every other weekend somewhere in the south. This fall coming home from a race the front seam on the cabover started coming apart showing us water damage. I put a 4" wide Externabond patch on it which held till I could get to work on it.

 

Now is the time to get dirty. 

This might not be the corect way to do things, but it is the way did it.

 

My friend Marc in the above pic.

Without him none of this could be possible!!!

 

As we tore into the RV we found way more rot then expected.

Nothing else to do but tear it out and decide how to rebuild.

Sides beside the cab were rotted as well so we tore that out as well.

Got pics flip flop here a bit. Here are the new cab side pieces covered with new sheetmetal and ready for paint.

Here is the side new side panel made from marine plywood and sealed with marine sealer.

Won't ever rot these out again. 

Built a new header and framing to suport the weight thruout and before I could get on top to take the outter skin off.

Also got the cab sides painted and installed.

Here is the outter skin  off with alot of the new framework exposed.

Bottom marine plywood temporarily installed so as to get the right contour with a plainer.

 Bottom plywood glued and screwed together coated with

marine sealer.

Next we will liquid nail the bottom sheetmetal skin on and roll with laminate rollers like we did the cab side pannels.

 

Hopefully I will be adding more of our progress in the near future.

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My friend Marc got some painting done for me while I was at work.... Now that is a pal!!!

 

Section over cab.

Got the skin on after work yesterday with liquid nail and laminate rollers.

 

New skin for the outter top.

The original skin had a window in it and lots of corrosion. We were going to patch the skin but after taking a close up look after it was off, a new skin was in order. No front window in the new build so no more leaking window!!!

All the sheetmetal came from a local race shop that builds dirt track race cars(Carolina Performance owned by Kip Cochren). The sheetmetal came in 4' by 10' sections for $76 bucks each. The sheetmetal was factory coating but wrong colors, so no need for primer. Just scuff and spray with automotive single stage paint to match RV's color. Added some flex agent in the paint so as to help paint from cracking while installing. Loose sheetmetal is as wobbly as spaghetti noodles so anything to help keep it from cracking while installing is a plus.

The top skin had two bends in it and was replicated with a 8' metal brake by Mr. Cochren.

Holes were drilled by Marc for the marker lights.

 

 

Side and bottom trim peices were painted also since they were off and needed a coat of love as well. Going to let dry for a couple days then start installing outter cabover!!

Can't wait!!!

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The saga continues!!!

Got some more progress done today!!!

Things are starting to come together.

 

Outside wood brackets made to hold the bottom section up while we tighten clamps inside to pull it tightly into place.

 

 

These clamps were on both sides to bring it straight back slowly into place.

We had already put double sided Externabond on the rear seam that will be flush when we get it pulled all the way back against the side cab panels.

 

Pulled tight!!!

Screwed from the inside so as to pull the bottom section tightly upward against the framework.

 

Between the cab metal and the bottom of the bunk is a rubber gasket. To the inside of the gasket I caulked with BIG STRETCH caulk. Then added 1" peices of wood that screwed and mashed the cab and bunk tightly together pushing the caulk out ensuring a good seal.

 

Tore out the rest of the rotted framing.

Now all the rot is gone.

Hopefully tomorrow will add some new structure and framework to the front.

 

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Another eveing and things seem to be coming along.

 

 

Here I am using a finetool scraping the last of the sealer off of the roof seam.

Gotta be clean so new sealant holds good.

 

 

The inside ceiling goes in first so it can be pinched between the outside framing just like it was from the factory. I am using FRP from Lowe's for the new inside ceiling.

 

 

Inside veiw. I will have to paint part of the  old ceiling a brighter white to match but that will come later. Sorry the cell phone doesn't take good inside pics.

 

 

Another outside veiw with one of the outter braces run across the bottom.

Until tomorrow!!!

 

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Today we added a few suport beams and framing, wired marker lights back up, insulation and outer paneling for added suport behind sheetmetal.

Just a couple hours but added results.

I will keep plugging along.

 

 

 

 

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   Showed some real progress today!!!

All the things we have been working on has led up to this point.

 

 

Outter skin !!

Took three grown men to finagle this wobble peice of sheetmetal into place.

Started using screws on the bottom edge and then worked up the sides finishing off at the top seam.

 

 

Used Big Stretch caulk on each screw head and along the top seam.

 

 

Then roled rubber roof patch along entire seam rolling it down tight. I used 6" wide rubber roof patch which was 16' long. Way more than the 8' peice that I needed but I am sure I will find a use for the extra sometime.

I had used this on the roof this summer not knowing I would have to tear it off for a cabover rebuild.

Let me tell ya, this stuff STICKS!!!

Took me hours to get the old stuff off. I am sold on this stuff !!!

 

 

Got all the trim peices in place.

Had to do some stretching and pulling but got the side trim on.

I used Durabond 1" on the seams and putty tape behind the trim peices.

 

 

Tomorrow I will be caulking beside cab and on both sides of all the trim peices.

Also need to install the marker lights onto the front cab sheetmetal.

Still have lots to do on the inside but the largest part of the rebuild is behind us.

I am very pleased with the outcome thusfar.

 

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Outside of the shop for the first time in a month.

Outside is done!!!!

 

 

Here is the inside bunk pieces being sprayed with lacquer.

 

 

 Installed!!

All that is left to do is a couple interior pieces.

Again I can not thank my friend Marc enuff for his tools, acces to a big shop, time, and know how.

Also I want to thank Joe Morgan for the use of his cabinet shop (Joe Morgan custom cabinetry of Franklin NC) and getting us access to a shop big enuff to work on the RV.

 

I did not keep up with hours involved but materials was around a grand. Lots cheaper than RV repair shops for sure!

Hope this blog helps others with their Class C cabover problems.

Thanks for reading.

 

 

[Bonnie Geddes]

Wow a huge undertaking..so nice to have such good friends to help..looks fantastic

[Aaron]

Very well done!

[Vicki Porter]

Great job!!  Wish you were down my way -- that's exactly what I need done to my RV.

[Kevin Town]

BEAUTIFUL JOB!....Looks very Professional and beautiful finished, Nice work!

[j pierce]

nice work, way beyond rv shop quality.