My cabinets are currently at Franks Trailer Works in Baltimore getting all fixed up and made beautiful. Problem is that my stove is in central New York, and Franks needs a measurement. I'm posting this picture to show the dimension I measured. I love technology!
Today I started welding up the frame cross member and support plate. I Klecko'd the support plate to the trailer skin, then positioned the cross member between the main frame rails.
Once everything was in place, I tack welded the cross member to the frame, and then tack welded the support plate to the cross member. That made sure everything was exactly where I wanted it. After that, it was a simple matter of grinding the tack welds off the cross member and bringing the cross member / plate into the shop for welding up solid.
My shop is currently, how you say, a mess. Interior skins are piled here, belly pan wraps are piled there, j-channel strewn about with a liberal sprinkling of interior window frame trim to add to the chaos. Add in your normal household fix-up projects, and you have a real dump. What the heck. I'm building things in there, not getting the space ready for a Better Homes and Gardens photo shoot. A clean shop is a shop that's not being used to it fullest potential.
Look at that stack of dimes. My little 110v MIG does a fine job of melting the metal. I could have welded 5 or 6 one inch welds along the seams and it would have been plenty stong enough, but I was having so much fun I decided to weld the entire seam up. I was talking to my friend Steve a while back about this little project (ByamCaravanner on AirForums), and he made a simple comment. He said something like "Metal does wierd things when you weld it". Well, Steve, you were right. The support plate developed a nice bit of warp from all the heat. Hopefully not enough to bother anything, but I'll find out when I go to mount it on the trailer. If I have to, I'll ditch my work, start over, and chaulk it up to experience. I know I can build this piece better, and better is the enemy of good enough.
Next, I transfered the angles from the wood onto the c-channel and cut it with the chop saw. This tool is indispensable for any kind of steel work. I cannot imagine making those cuts with a hack saw.
I was going to try to re-use the support plate, because it has so many holes that need to be aligned with the holes that are already in the skin of the trailer. Unfortunately, the plate was just too far gone. Also, I did not realize when I started that the plate actually goes all the way to the bottom of the c-channel and is not just welded along the top. In order to transfer the holes precisely, I tack welded the old plate to the new plate and used the old holes as a guide for drilling my new holes. Once I was done drilling, I carefully ground off the tack welds and I had an exact duplicate of the original plate.
Here is the almost finished piece, all mocked up. The next step will be to Klecko the plate to the skin of the Airstream, tack weld the frame cross member in place, and then once everything is lined up I'll tack weld the plate to the cross member. Then I'll grind the tack welds off the frame so I can bring the entire piece into the shop and weld it up solid. I don't want to weld it solid with it on the trailer, since I'm afraid the heat will hurt the aluminum skin. Once it's all welded solid, I'll do the final installation and welding of the new frame cross member / support plate onto the frame. Oh, I'll also cut the bottom inch of steel off the support plate that sticks down below the c-channel so it looks better. I needed a piece of steel plate that's 24 x 11, but the closest I could find in the drop room was 24 x 12. That's OK. I'll get my cutting wheel out and smile the entire time thinking of the money I save by not having Steel Sales cut me a piece to size.
This section of frame has been weighing on my mind. The weather here has been nasty, and work has been absolutely nuts dealing with the flu outbreak. Today, however, it was a beautiful day and I had some free time on my hands. Time to get at it. I spent some time building a brace to hold the shell off the trailer for when I cut away the support plate. Much to my surprise, the shell actually lifted up about an inch rather than coming down. The support beam I put in place fell once the shell lifted up, barely missing hitting a window. The Airstream gods were watching over me, I guess.
Bad, bad rot. It's amazing what the tin worm can do.
Tuesday I'll head to Steel Sales and buy replacement steel and begin fabrication. I have a few other small holes and weak areas to fix on the frame in other spots, too. I should be able to get that all fixed up pretty easily, then I'll POR-15 the frame and be ready to put down new wood for the sub-floor.
With the entire front half of the trailer gutted and the back end still complete, the tongue does not have enough weight on it to allow the trailer to be cranked down to level where I need it to be. The trailer would balance on it's axles with the tongue jack off the ground. 250 pounds of barbell weight took care of the floating tongue.
Thin, thin steel. Strange that the plywood just above this section was solid and showed no signs of rot. It will be a process of welding additional steel underneath this crossmember to make it solid once again.
Both step outriggers look like this. I'll be replacing them with new ones, and also buying a new step for the trailer. The step that's on there has rust holes through the tread and the studs that ride in the track are just about worn away. I just hope I can find a step that looks right on a 1961 Airstream and not one that looks like a take off of a new SOB trailer.
That front cross piece? Yeah, it's bad. I'll be cutting it out and fabricating a new piece to go in there. The support plate is welded to the cross piece. The trick is going to be getting everything back in the exact same location after I take it all apart. That's okay, I enjoy a challenge.
After getting the carpet out, I started pulling all the cabinetry out to get it ready to send to Frank. It's amazing how much easier it was to get this end of the trailer apart than it was to do the back end. Having already experienced it once, I was able to get the screws apart with minimal frustration. I knew which screws would be a bugger, and I knew how to handle them. All of the furniture came out without damage, and will make great platforms for Frank to work his magic on.
The cabinets held up quite well, considering the fact that they are nearly 50 years old. Here's a couple tips for anyone who will be pulling their old furnace out: 1) Make sure there are no active wasp nests living in the exhaust shroud. 2) The furnace exits the trailer through the cut in the skin, and not through the door.
I have 2 spots of floor rot. This one was hiding behind the pantry cabinet in the galley. I will be pulling all of the old subfloor back to the wheel wells, and possibly pulling the piece between the wheel wells. Further investigation with my screwdriver will tell me what I need to do.
All of the cabinetry is out of the trailer and taking up space in my garage. I'll get this flooring replaced, then get the trailer over to Don Stanton's for Zolatone, and in October get the cabinets to Franks Trailer Works for rebuilding. That will give me through the cold of winter to get the cabinets installed, and springtime to get ready to camp.
It doesn't look as good as when I will have an Astrodome installed, but it looks 100% better than it did. 
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