Saturday, September 01, 2012

1980 Starcraft Starmaster 1906 xl Restoration


Here's a picture record of my PopUp Camper restoration. The story really starts here on the fantastic popupportal.com forum. Without the info and encouragement there I would never have gotten very far.

After tearing things to bits for several days this was the first thing to go in the right direction. I had to lap and glue two 1/4" ply sheets to be able to make 11' lengths of 1/2" to make the new roof side bars

Here's the new side bars. We can't (easily) buy 12' sheets of board in the UK. The old aly from the roof is in the background. I had scraped all the polystyrene off it, very strongly glued. At this point I thought I would use the original aly roof on my new frame.


At 7' wide the front and back boards were able to be cut from regular 1/2" 8x4' sheets. I used external W&B grade ply throughout, not marine.
New roof frame about done. Was surprised how long it took me to make. woodwork is not my forte. The flags went up for eurovision song contest!


compared to the original manufacturerI added the three addition crossbars on the roof to prevent sagging. Have to say my roof still sags a bit...
after spending several hours fettling the old aly skin, when i found several corrosion holes in it i decided i needed something better. the last straw was after i placed it on the new frame and when it rained it still sagged into the centre seam and started dripping. Why did they put a seam down the middle???




I decided I wanted a roof skin without a seam. It took ages to source this but I managed to get an end of roll piece of 'roofing coil' it used to make roofs of artic trailors and trucks etc. we had a manufacturer locally who was very helpful.

the roofing coil sheet is 8' 4" wide. ideal. i only need 7'. It is, at 0.9mm, thicker than the original. the only dissapointment was I couldn't get it with a stucco effect, this is just smooth. It is a devil to handle when you undo the coil - spings flat
To bond the wooden frame to the aly I made a wooden 'former' which replicated the curvature of the roof, laid the aly on it, glued the wooden frame too it using 'no more nails' type glue, then weighed it all down with part from the plough I'm renovating.
I bonded the polystyrene sheeting to the aly and wooden frame using special bostik contact adhesive that was designed not to melt styrene. At £30 for 5 litres it wasn't cheap and it took it all.
To make the roof lining I bought white faced hardboard which has a plastic coating similar to the original. I used the same glue as above, but this has not worked well at all. My sheets are peeling off the styrene and this is adding to the slight sag in my roof I suspect. ahhhh!!! I intended no nails in the middle of my roof, just gluing the sheets and using the original plastic jointing strips to cover the gaps between the 4' sheets. I have had to whack in some additional staples into the additional wooden struts I added. not good.





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around the same time as getting the roofing coil I jacked up the body of the pup to drag out the chassis. By this stage I had decided to change the front hitch and axle to a UK one from a donor caravan. The chassis was in for serious surgery.






The oringinal leaf spring axle. big question was could i use an axle from a donor caravan in it's place. they were all torsion type, not leaf spring.

I used 100mm x 50mm box to make my new A frame for the chassis. Here's the new front bar tacked in place. Someone said, "don't bring home a wreck Mark and make the back garden look like a scrapyard"

you can see my donor torsion axle on the left. quite amazed to find that the mounting plates for it fitted quite nicely to the chassis where the spring hangers had been mounted. i just needed to make a plate to bolt the two sets of holes together
Goodbye Sur Act III 2" ball hitch. Not sure all my angle grinding was very neighbour-friendly...

The axle fitted in nice between the inset part of the chassis
the new steel for the A frame was considerably heavier than the original - i'm an old farmer after all









I used the grid of the patio slabs to make sure everything was square.I should work for NASA!

Getting there, winding gear box tacked in place too now.


soon after this the chassis went to be shot blasted. Thanks to lads at CP Blasting, Creswell. they also painted the chassis for me.

i had hope that the 13" wheels that came with the caravan axle would fit. Unfortunately they were just a bit too tight to the wheel arches. This was exacerbated by the fact that the new axle was 2 " wider than the original

here's the original wheels. they are 12" 5 stud 4.5" pcd. I had to get 12" 4 stud 100mm PCD to fit my new axle. Fitted 145R12C tyres. Trailer sits real nice and level with those behind the range rover, just like it did with the original gear




chassis bac from the shot blasters. should be good for another 32 years now! the colour is chosen to match the original colours. The 'mood board' for the colour pallate is described as something unmentionable by some members of my family. For anyone interested my paint guys matched the colours to BS4800 colours thus; the brown - 08-B-29; the red - 04-D-45; the cream - 10-B-15. these colours appear not to have a standard set of names under the BS4800 scheme.

At this stage, knowing the deadline was tight Andy turned up to help for three days. you are a star!
Also Owen and Gertjan helped.



hitch on with brake linckage attached. Owen and Gertjan put all the brakes back on. I had removed all that before shot blasting, didn't want to get chilled iron in them.

had the mount the winding gear slightly higher than normal to allow the brake rod to pass under. Works fine!

Winding gear back in. owen did this. i also removed the little pulleys from the chassis before blasting.

brake balancer. brake a re really sharp!

amazingly the holes i had to drill in the new A frame for the winding wires to pass through lined up nicely! The wire I bought to remake the broken one was 2mm 7/19 316 stainless from ebay. I used 2mm ferrules. I couldn't run to the proper tool for crimping these ferrules (£50), so a squashed them in the vice then used a cold chisel to crunch them more down the middle. Don't know if they'll last for ever, but they've kept the roof up for a five day stint so far.


After the aly was bonded to the roof i was able to trim it to the proper width.



Here I'm testing a little bit  of the aly to see how well it wraps around. I should have wainted until the aly side plates were on of course. getting over excited!

 I used at etch primer on the bare aluminium. then two coats of base, four coats of topcoat.

 you might have seen that when i got the pup someone had decided to paint the lower panels cream to match the upper part.

here they're going back to the original red


 
 Some of the red panels going back on!


roof, new wheels, and top fridge grill all getting top coated

ditto.

At this point with 5 days to go before the August bank holiday deadline Myles came over to help put the roof on. Thanks mate!

roof on!



At this stage there were still several hours of frenetic activity. wiring of lights, new floor to screw down, all hatches to put back on, canvas to hang, roof seal to insert (fiddly), etc etc. Like the whole project it all took a lot longer than I'd imagined!! Spent three hours on it the morning we went away. i have a very patient wife

But - we're camping!! greenbelt 2012, August bank holiday! Everyone amazed I'd got it finished, including me. It was a shell inside, but sound to use with a new floor. I rigged the original cooker to the LPG. We'd had the beds recovered. The weather at greenbelt was absolutely terrible, including torrential downpours. the pup had a full test but was totally dry throughout!



The canvas was all pretty good apart from two top bits of rot in one of the bed awnings. thanks to M & N Canvas Services Ltd, Sheffield who turned a repair around in less than a week and all for £20. they had some old stock canvas that was a great match for the colour too.


thanks to all my friends for their help. not least Kenny a stevecaseys.com RV. He supplied original parts which I was pleased to be able to get. Thanks to Ross anf Jennifer at Lilleker Antique Auto for shipping those parts to me

Saturday, July 07, 2012

Mythtv tweaking and nfs

Sound on mythlounge:
(newer setup, Dec 2011, using S/PDIF mobo o/p) choose:
ALSA:dmix:CARD=NVidia,DEV=1
again only STEREO works
this is using the "HDA NVidia, ALC888 Digital" device
these allows firefox sound to work with myth.

playback setting:
VDPAU High Quality



NFS server: exports need adding to /etc/exports on the (file)server

1. install:
apt-get install nfs-kernel-server 

 
2. on the server create the /export shares:
root@server:/home/markp# mkdir -p /export/Music_flac
root@server:/home/markp# mkdir -p /export/Music_mp3
root@server:/home/markp# mkdir -p /export/photos


3. bind the /export filesytem to the actual locations, add to fstab so happens auto on boot:
#NSFv4 server share settings:
/home/markp/Music_flac /export/Music_flac      none    bind    0       0
/home/markp/Music_mp3  /export/Music_mp3       none    bind    0       0
/home/myserver_groups/photos   /export/photos  none    bind    0


4. set the nfs conf options as suggested at:
NFSv4 setup from ubuntu community.

5. place the exports in /etc/exports:
/export       192.168.1.0/24(rw,fsid=0,no_subtree_check,sync)
/export/Music_flac 192.168.1.0/24(rw,nohide,insecure,no_subtree_check,sync)
/export/Music_mp3 192.168.1.0/24(rw,nohide,insecure,no_subtree_check,sync)
/export/photos 192.168.1.0/24(rw,nohide,insecure,no_subtree_check,sync)


NFS setup for client

1.:
sudo apt-get install nfs-common

2.For mythmusic set directory as /home/markp/Music_flac
For mythgallery (photo viewing) set directory as /home/myserver_groups/photos
The above directories allow mythfrontend on the main fileserver to use their real locations

3. create the mount points referred to on the client:
sudo mkdir -p /home/myserver_groups/photos
mkdir -p /home/markp/Music_flac
mkdir -p /home/gracep
mkdir -p /home/meganp
mkdir -p /home/crossing_groups
mkdir -p /home/markp/myserver_groups
mkdir -p /home/sheridanp
mkdir -p /home/markp

4. add this to fstab to mount the nfs shares on the client on boot:
#nfsv4 mounts
192.168.1.10:/Music_flac /home/markp/Music_flac nfs4 _netdev,auto 0 0
192.168.1.10:/photos /home/myserver_groups/photos nfs4 _netdev,auto 0 0




nfs4 file permission issues: although the flac files could be accessed fine on the client, the photos wouldn't allow access to the subfolders, 'permission denied'
chmod to 777 on the server fixes.

Album art issues in mythmusic:
although I thought mythmusic was picking up the image that it can display when using the the visualiaztion 'album-art' from the flac tag, it would appear it doesn't. Rather it is relying on a jpg being in the folder of the flac files. This file can be called anything.jpg but cannot be a hidden file, ie start with a full stop.

Friday, July 06, 2012

Recognised & Regarded vs. Authorised to Service

R&R and AM -  the low down:
Recognised and Regarded.  This is no longer the category which applies to people in LEP situation.  The category is "Authorised to Serve" (AM).

(This change occurred six or seven years ago.  R and R means that a person
is fully under the discipline of our Conference, resulting in people being
fully under two disciplines, which obviously doesn't work. AM means that a
person is under the discipline of their own Church but authorised by and
accountable to the Methodist Church for relevant parts of their work.)

As soon as we know who the person is, we can start the ball rolling (it
must come via the District).  The President of Conference would be asked
to approve it.  I've never known a case of refusal.

Friday, June 01, 2012

fonts in Ubuntu

Put extra/new fonts in /usr/share/fonts/truetype

Wednesday, May 30, 2012

setting up new users etc in new ubuntu install to sync with UIDs at TC



logout of gui, drop to shell (ctrl+alt+F1).

sudo adduser <newusername>

then add newusername to group sudo

exit

login to shell in that new name

sudo usermod -u <newUID> <usernametochange>

Sunday, April 22, 2012

Mobile phones in car

trying to do a number of things here:
1. Charge two phones, samsung galaxy and iphone
2. pipe sound from either phone via car ICE

the usb+3.5mm stereo to iphone connectors are powered via a cigar socket to usb adaptor which has an additional usb A type socket soldered to it's board

Saturday, April 07, 2012

freesat mythtv firmware hauppage problem

Although the card is seen on the system, and in Mythtv, the Hauppage DVB-S2 tuner needs some non-free firmware to make it work:
cat /var/log/kern.log
Apr 7 08:35:22 mythserver kernel: [ 711.136979] cx24116_firmware_ondemand: Waiting for firmware upload (dvb-fe-cx24116.fw)...
Apr 7 08:35:22 mythserver kernel: [ 711.140459] cx24116_firmware_ondemand: Waiting for firmware upload(2)...
Apr 7 08:35:22 mythserver kernel: [ 711.140466] cx24116_firmware_ondemand: No firmware uploaded (timeout or file not found?)
Apr 7 08:35:22 mythserver kernel: [ 711.140473] cx24116_cmd_execute(): Unable initialise the firmware


It won't tune until the firmware is installed, so:
sudo apt-get install linux-firmware-nonfree

Reboot, then :
markp@mythserver:~$ dmesg | grep cx24116
[ 37.916332] cx24116_firmware_ondemand: Waiting for firmware upload (dvb-fe-cx24116.fw)...
[ 38.071137] cx24116_firmware_ondemand: Waiting for firmware upload(2)...
[ 42.916930] cx24116_load_firmware: FW version 1.26.90.0
[ 42.916948] cx24116_firmware_ondemand: Firmware upload complete
[ 45.166018] cx24116_firmware_ondemand: Waiting for firmware upload (dvb-fe-cx24116.fw)...
[ 45.171222] cx24116_firmware_ondemand: Waiting for firmware upload(2)...
[ 50.036655] cx24116_load_firmware: FW version 1.26.90.0
[ 50.036675] cx24116_firmware_ondemand: Firmware upload complete

mythtv tuning now works...