The Ultimate DIY Story!

Our floor problem started in front of the stove. At first I thought it was a “void” in the plywood. Silly me, after investigation I discovered that the floor was just ordinary ½ inch “OSB” and protected from the elements by a black membrane applied to the underside of the OSB. Being a retired carpenter/ builder fixing this spot would be a no brainer. I reasoned if water had found it’s way through the protective membrane in the center, where else might it have got in?

With my trusty ice pick I started to probe areas where the water really goes while towing in the rain, around the wheel wells, sides and back corners. We have never, not even once, had a drop of water on top of the floor covering so it was now obvious that the water gets through the protective membrane while towing in the rain. The trapped water then starts to break down the glue in the OSB. I figured we had towed our unit about 40,000 miles and as you know, it rains sometime when you go a traveling.

We went to the Branson Rally hoping to find others with the floor problem to prove it was not just our unit and by chance find an “avenue” for liability. We had factory reps look and make promises in good faith but I knew in my heart our little camper was doomed. We traveled home to Massachusetts and decided to remove some of the cabinets to see if the water damage had spread to the outer edges, which would make replacing the floor almost impossible without removing the “WALLS”. Think about that for a while.

It was a very sad afternoon as we sat looking, almost with tears in our eyes, at the extent of damage to the floor. We made “the calls” to the factory, very nice folks but no new camper coming our way. We now knew it was indeed over for our beloved Aliner. But, we love our Aliner, and life without it would not be the same. There has got to be a way! (Wait while I get another beer to help me think.) We could have a “fire”. It could “disappear”. I mean there are no options here! Then Pauline came up with “what if”.

What if the factory would build and sell us just the bottom? Lower walls, floor, wiring harness and tail lights. YA! Just an empty box on the new longer frame, set up with storage box on front, lengthened rear bumper, and 10 inch brakes. Then, I would transfer all the cabinets, appliances, triangles and roof sections to the new base. But would the factory go for this?

We had been in touch with the factory several times online, so I thought I would send them an e-mail with this latest proposition. I poured myself a glass of wine and sat at my computer and composed a beauty of a letter. A girl named Julie read my letter. Julie emailed me back and instructed me to call the factory and talk directly to Dave Tate so the timeframe for building our base unit and price could be worked out. I called, we talked, and things were looking good. I had to work through my dealer to place the order. He was super, a fax here, a fax there and the next thing I knew, we could pick up our unit at the factory in three weeks.

We arrived at the factory on the agreed day and met Julie. She took us on a personal tour of the factory and as we toured I got advice on some of the issues that would confront me as I did the swap over. Everyone was just so nice and helpful. Folks did I mention this was not a freebie? ....but the very best solution for our situation. We did the paper work, said our goodbyes and were off.

I had a pipe and canvas car tent erected on our patio to put our new base unit under while I did the swap over. I had already gutted our Aliner, and started to place the old cabinets about the new base and decide while I was doing this why not make some changes. Changes that would reflect our taste in decor and maybe at the same time improve functionality.

I decided to start from scratch and build all new cabinets, move some things around for convenience and weight distribution at the same time. We decided to go with all white laminated cabinets and simulated black granite counter tops. I never was a fan of the AC sticking out of the side. It also robbed the space from the cabinet inside. We wanted more water storage, a drawer for pans, a microwave under the stove, and, and, and.

So I came up with a plan that put a new remote controlled AC center rear, floor level under the dinette table. I reasoned that when the table was dropped to make the bed, the cold air would blow towards the front, hit the angled wall and ceiling, swirl around and cool nicely without blowing directly on us. It does just that, and as an added bonus you barely can hear it. Now we have full depth drawers in the cabinet.

I moved the hot water heater and the battery to the passenger side under the dinette seat and a baggage door to access the storage space left. On the other side, starting at the rear, I have electric cord storage, 30-gallon water tank, converter and the water pump. This setup makes winterizing a snap. I put the microwave centered under the stove and a big pan drawer under the microwave.

While installing the refrigerator I added extra urethane foam insulation as space allowed. Across from the refrigerator we have four big drawers and as you come in the door on the right is the porta potty and a storage cabinet over. When the interior was finished we were ready for the roof and triangles.

With the information I got at the factory the roof installation went smoothly except for one thing. Our old unit had straight front and back walls inside and the new had angled walls, thus the old lift springs were woefully inadequate to help lift and lower the roof. Wow! Did that roof come down in a hurry! But a call to the factory and the right springs were on the way.

We just love our new and improved A'liner and are looking forward to showing it off at the “Rally in the Smokey’s” next May. Till then here are a few pictures."

by BT and Pauline Tremblay