Rebuilding a 1999 Jayco Pop Up (2 Viewers)

[Hornd]

Found this for $350 - Son of my Fathers Lifelong Friend. I think it was more of a Project than he Anticipated.

I think the pictures answer a lot of Questions.

Very Fun & Rewarding Project, but taking way more Hours than I anticipated.

Had intentions of Insulating the Floor but had no way to Make it Flush so Skipped.

Will be adding a Diesel Heater this Fall & 2 Solar Panels on Roof with Charge Controller and Batterie(s)

May add Load Bars on Top to Carry 2 Kayaks that weigh 40 Pounds Each

Weight of Camper is 1100 Pound Empty. GVWR 1800 Pounds - Tows Nicely without Auxiliary Brakes.

 

[Hornd]

Removed all 4 Cabinets in Interior including the Propane Line and Electrical and Water Line - 1 Hour

Removed the Floor. Found Rot at Front Right Corner and Along Rear. Water and Sun Takes these Trailers Out. The Sun Cooks the Sealant then water gets in unknowingly and Rots out the Frame.

Removed 9/16" OSB Flooring and Replaced with 3/4" Treated Plywood (2 Sheets) $106 from Menards - Took 10 Hours

Screwed down with Tech-Screws

Had to Lift off walls using Floor Jack as Walls sit on Floor.

 

[Hornd]

Trailer had Light Surface Rust.

Hit all that was Accessible with Wire Wheel in Angle Grinder & Drill

Sprayed with Fluid Film ($40 Amazon) and Astro Sprayer ($30 Amazon)

 

[Hornd]

Removed Rear Bed - 5 Bolts

Remove and Replace Aluminum Skin and Framing.

Glued Extra piece of Flooring to Skin with Liquid Nails.

Replaced Framing with 2x4 Cut down to 1" Depth.

Took 1 Night after work till 10:30PM