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Sunrader floor damage repair (hole through floor)


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Okay, 

Believe it or not, we didn't see the extent of this damage because it was so expertly covered up by the previous owner.  I think that the old axle snapped at some point and the rear tire tore a hole in the floor, but who knows.  When I started pulling back rotted wood it was a nightmare, but slowly it's been put back together and now I think stronger that ever.  



First I cut out all the bad.  Then I cut a square of aluminum to which I riveted to the existing aluminum and sealed with dicor.  Then I laminated in 1 x 3 crossmember using a kreg jig and screwed the aluminum into this.  From there it was a cut and fit job with foam insulation and 3/8 inch ply.  My wife went in with the fiberglass and built up the torn out wheel well and connected everything with mat and completely encapsulated the top side of the ply and the underside creating a complete bonded seal with the Aluminum.  I sprayed the underside with Rustoleum undercoating and we primed and painted the interior white.  
 
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Looks good.

In a millennium some archeologist will dig up that wheel well and spend the rest of his/her life expounding on what type of civilization created the sacred object. 

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