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Nancy Kroes' 1959 Rear Door Scotty Rebuild

picking up where page 1 ends. Jump to page 3.

Driver's side installed. That weird notch in the rear corners is necessary
because of my opting to use 1969 construction methods and hide the
support framing between inner ply and outer skin. Hope my idea works!

Passenger side installed

The old rear framing sitting in place just to give an idea of cabinet spacing.
This framing will be used only for a pattern. The door frame is sitting there too.

Here's the original rear framing. Kind of sparse.

My new and improved frame! I added sections from top to bottom along
both sides, and a piece along the bottom on both sides as well.
Used white cedar for my new frame - light but should be relatively rot-proof as well.
Just sitting in place, held by clamps, for this picture. No where near ready to install.

Planing rough sawn oak for the furnishings.
I bought over 1000 bd. feet from a local man who'd had an oak fall
and had another removed and then had someone come over with
a portable band saw mill and cut it up for him. I've had it
since 2003, so it is well air dryed and ready to use. At $600 for
over 1000 bd. feet, it was a steal. Of course I did have to have a barn
built to hold it all...

From 1 3/16" thick to 3/4 - ready to use

Brought over the 3 sheets of 1/8" beadboard panelling left over from
a house project and stored in my garage at least 15 years.
Very dry and slightly different than today's 1/4" version. The medium
walnut Watco Danish oil used on the 1/4" sides, on this stuff, didn't match at all.
Did a custom mix of cherry, light walnut, and golden oak and came
pretty doggone close to the color of the already finished 1/4" paneling.

Our test board. Just plain light walnut on the bottom &
then light walnut with some golden oak added and the top two have cherry as well!

All cut to length and oiled with 2 coats of the custom mix.

My neighbor's birch tree fell down and they gave it to me.
The bark will be used for one of the "furnishings" I'll be making for the interior.

Clamped the skin on to the new side. Wanted to see how close we came
to matching it. Pretty close (off because so much of the original sides
were rotted totally away and made a "best guess". Some tweaking to be done.

You can really see here how much higher than original my Scotty is now
sitting on its wonderful new axle. Many many thanks to Jerry Maurer for
turning me on to this axle - in my opinion it is way better than the one
Serro used originally. Those are the new wheels I ordered -
source is Low Cost Trailer Supply and they're linked on the tires and wheel page.
The tires are new too - Carlisle ST205-75-R15s.

There's my fine new oak boards on the left but my shop is mess!

Another view and I wish I'd shot around the corning of the drum sander
so you could see there was no open floor whatsoever.

After four hours

And voila! I have assembly space.
Next step to cut the oak boards into the useable sizes and
start assembling the frames for the new furnishings

Machined white cedar for the new wooden rear *door*

Glued up white cedar for the "porch" (folding step). This is sized for the
standard-sized door mat in my theme, which will be stainless steel screwed on.

LOVE my Grizzly drum sander. This is my second drum sander, the first was a
Delta. This one has its own dust collector which works great. No clouds of
dust in the air when I'm using it. The Delta was connected to my biggest
shop vac which plugged up the filter in minutes of use. It found a new home
with work colleague Bill.

The same platform after several trips through the drum sander.
This turned out far too beautiful to cover up with paint and a door mat.
New plan is to use a clear exterior finish on it. The door mat will
sit on the ground in front of the "porch"!

Rethinking my door too - I may leave it unpainted and go with the exterior
clear finish. If it doesn't hold up, I can always paint it later. Just seems
a crime to cover up such beautiful wood with paint!

Using the Kreg jig on the face frames. Used this for the first time
on the Shasta project I worked on last winter. LOVE it.
How did I manage to live so long without one, I'll never know!

Face frame for the bed is done.
Going 4 drawers here. Did only 2 deep ones on my
previous Scotty rebuild. Think 4 is better.

The bed face frame & drawer supports are done.
This piece now moves to my dad's shop as he's graciously agreed
to make my drawers for me. Thanks Dad!

Lower kitchen cabinet front frame - cut out but not assembled yet in this pic.
It has been assembled now and awaits the rest of it. Had wanted to put
the .5 cubic foot electric refrigerator I bought in the upper left, but not
enough space over the wheel well to do that. So, refrigerator upper right, with
a drawer below it. Pots and pans drawer on the upper left. False front below it.
The middle has been redone - a short drawer and 2 deeper drawers below it
and two false "drawers" below them, in front of the wheel well. The
refrigerator will be behind a wooden door that will match the rest of the cabinet.

All of my new LED lights arrived! Even the license plate light is LED.
The lights all have plugs and are self-grounded. Not sure yet how I'll do that.

A close-up of the license plate light and backer. The backer is powder coated
black and will look nice with the black rims around the LED taillights!

Bedside stand framing is done and awaiting new drawers.
Bottom opening will be a panel - wheel well is behind that spot.

Lower kitchen frame is done and awaiting new drawers
and, best of all, it FITS!

New flooring on the left. New plastic laminate on the right.
I was going to make my countertops out of wood until I found this laminate.
Will also be covering all the drawer bottoms using this laminate.
Bought a 4x8' sheet of it - special order at Lowes. It's a Wilsonart product.

My dad is making my drawers and using the drawer bit I bought.
He's got several of them cut out already. He'll cut bottoms to rough
size and then I will laminate the Wilsonart to them. I will also
use a Watco Danish oil to *color* the drawer sides before assembly.

My very cool (we think) cabinet and drawer handles. The faux antlers
will go on the 4 drawers under the bed and the faux twigs will go on
the closet, the bedside stand and the lower kitchen cabinet.

(excuse the dust in the air - made the picture funny)
Thank God for Jeremie - using my circular saw to cut one inch off the rear
at a 20 degree angle. Took 3 passes and still didn't quite make it all the
way through. A chisel took care of the rest of it and...

The 12 volt reciprocating saw got the very ends where the other
saw couldn't go.

After sanding smooth - coated the new cut joint with Herculiner

The outside of the sides got 2 coats of white exterior enamel and
the bottom edge and 6" up the sides got Herculinered. I wasn't going
for a zebra look here - those other stripes of Herculiner are where
there were cracks in the outer ply of the plywood.

Several of the drawers are done, with their beadboard fronts on them

And several more have their fronts glued and clamped.
You can see the plastic laminated drawer bottoms. Interiors
of the drawers were stained and polyurethaned as well.

The upper kitchen cabinet is all cut out and almost all assembled.
This is out of number one quality pine and will be distressed and painted.

My first attempt at twigging!
This was a 3/4" maple sapling that I cut in half using my tablesaw.
Process worked remarkably well. I didn't like the gray bark color
so have stained it using a dark - with a bit of reddish, stain.
The twigs will also get a coat of glossy polyurathane before they
are attached. They are going everywhere! Lot of them. Lots and lots of them!

Ten of the eleven drawers and the bedside stand, after
a coat of Watco Danish Oil in Golden Oak. They have since
received their first coat of satin-finish quick-dry polyurethane

The lower kitchen cabinet and the bed front after a coat of Golden Oak

Since I was so happy with the POR15 on the Scotty frame, I
bought another POR15 product - Metal Mask. This is the door frame
and this product is supposed to give it the look of new metal.
So far looks great - supposed to harden to a very durable and hard
finish after four days.

The upper kitchen cabinet after one coat of the base color blue.
One more coat of blue, then two coats of a cranberry Milk paint.
Then, sand through to see blue and also bare wood. Finish with a coat of stain.

Polyurethane is dry - set pieces in place for a dry-fit *and*
to get out of the way while other work continues.

Bedside stand - 2 drawers, and a panel below

Front of bed - 4 drawers, 2 top, less deep than the bottom two.
I think this will be more practical than my previous Scotty where I did 2 deep drawers.

Lower kitchen cabinet and the painted upper cabinet.
The upper left drawer needs tweaking. A false drawer below.
In the middle, 3 drawers, with 2 false drawers below.
And to the right, a .5 cubic foot refrigerator will reside behind a door
and a big drawer is below - also needs tweaking.

Close-up of the upper cabinet.

Looking in from the front. There's a 2" lip on the bottom of the upper cabinet,
which will hide a small modern fluorescent fixture that will be activated with
a light switch to the right (or left, from this view) of the door.

LOTS of under bed storage, which will be accessed from a panel
under the mattress - using gas prop arms. No outside access door on this Scotty.

Morticing for the upper cabinet's panel doors

Tenoning for the panel doors

Yay, a perfect fit!

Slots cut and panels dry fitted.

The finished cabinet - with my painted RD/bears camping scenes

Special ordered this product from my local NAPA store.
WOW, is all I can say. You just use a tiny wad of that fabric and rub it
and then wipe with a clean cloth (or paper towel)

This is a piece of RD's lower rear skin - shines good enough for me!
This stuff is fast too - this tiny piece took about 30 seconds to polish
and a minute to wipe the black off with a paper towel

And a finished eyebrow, next to an untouched one

The panels for the rear wall are cut, stained, & first coat of poly

I wasn't sure I was going to put the twigs around the drawer fronts.
But, just laying cut twigs around one, I LOVE the look so will!

Cut the oak beadboard panelling - got it stained and 3 coats of poly
and installed on the rear wall frame. Just clamped in place right now.

And, seen from the rear. You can see the 3 electrical boxes.
One on top for the light in the kitchen, one on top for the outside light
(which will be powered by a lightswitch) and one for the refrigerator.

Windows were all taken apart and polished. The bars were a rusty mess
and received a coat of the POR15 "Metal Mask".

The removable part of the bars. And, lucked out, one of my bars was
missing the channel the crank rides in. I had ONE in my Scotty stash. Yay.

Previous owner had painted the inside of the windows white.

I painted them dark blue to the paint custom matched to my floor.

The siding polishing has begun. Far left untouched.
Middle, polished with liquid Barkeeper's Friend. Right, after Duragloss.

The porch (step). Ready to finish the legs and then add the exterior
UV protected clear finish and should be good to go.

The new closet pole - making this shape and size so
the hangers won't rock themselves off while traveling (my theory anyway)

Front side of framing for the new closet -
it's resting on the oak beadboard front panel

Starting to glue up the back wall framing for the closet.
Still loving my Kreg jig! Makes really fast work out of framing.
Loving all my lithion ion drills too - I now have FIVE of them - woo hoo!

Front frame attached to rear frame and pantry shelves installed

As with my drawers, added Formica to the pantry shelves

Frame over at my dad's shop where the trailer resides.
Yup, it fits.

And, so does the face panel of oak beadboard

Door is cut - its a bit larger than original

Lots of shiny skin and trim!

I was afraid of this. Looks like someone added a bigger than original
light fixture and cut a really bad hole for it.

My new light isn't as big as the hole.  Hmmmm.
I may have to do a ben - cut a new piece of aluminum plate to surround it.

Putting the new plug end on the 30 amp cord.
My stainless steel fixture takes the plug that twists and my cord didn't.

All ready to use!

Back at home - closet door is cut and glued.
Used two pieces of beadboard, glued back to back.

Door stained

Closet and the rest of the drawers/panels stained

Front angled piece cut out of pressure treated & installed

And, front side of it Herculinered

Oh no! The last bit of the original Rear Door burning!

Storage shelves added to the closet framing. Mabel figured she might
as well utilize what is otherwise wasted space.

And, from the backside. The rear wall will of course be behind the shelves.

Refrigerator shelf - w/Formica installed

And, the refrigerator fits!

It will be hidden behind a door

The fluorescent fixture under the upper cabinet

Rear wall installed as well as all cabinets now installed

Closet is installed

Looking in the "Rear Door"

Closet & bedside stand through the "Rear Door"

The rear wall from the outside with door frame sitting in place

The new unbeaded (and unstained) oak 1/8" plywood. Looks much better!

And, cut to 76" and stained. A definite improvement over the 1/8" beaded
oak that didn't quite match the 1/4" beaded oak plywood.

Underbed drawers in place- working on the bed frame

Bed frame finished and installed

And, bed frame as seen from the front

120 wiring done and ready to install breaker box under the bed

Lower driver's side skin installed so I can install the plug outlet
and the outside outlet

Outside outlet installed (need a 2 1/4" hole saw to install the power outlet)

Hole cut

New stainless steel power outlet installed

Takes a locking 30 amp plug

New cordless Black & Decker Flex vacuum - works great
and small enough to tuck into Rudy's storage space

Wiring finished and tested

Vintage hammered aluminum porch light works

The under-cabinet light works

And so do all of the outlets - this is the bedside lamp

The under-bed drawers are boxed in -
this gives me a 3/4" x 15" x 41" storage space for papers

Bed platform plywood is in place

Outlet covers in place

Definite progress has been made

Running lights are installed and WORK!
I used non-standard (for a Serro Scotty) LED lights - brighter=safer, IMO

The LED taillights, and in front of the orange-handled pliers,
the LED license plate light. All WORKING!
I installed with only one ground to the frame because each of these
lights had a ground wire, so ran a ground wire to each light.

The cool ss "wings" on the side markers, I think they look really
great with the LED bee hive lights

Closet door installed with mirror.
Drawer pulls installed

More drawers/pulls installed. The bottom left, and 2 bottom middle
drawers are fakes, just panels, because the wheel well is behind them.

And, another view

I took apart the non-Scotty access door I bought at the rally last summer.
Inside of the door was unpainted aluminum - outside was white. Flipped
the panel around so aluminum would face out. My dad is putting it back
together for me with help from brother-in-law Craig. Thanks guys!

Just needs its locks reinstalled, a hole cut in the Scotty
and it's ready to install. I bought an eyebrow too, which will hopefully
disguise the more modern than my Scotty door.

Ceiling plywood is on and went very smoothly.
I redesigned the back wall/ceiling of this Scotty was
just a tad worried that my design would not work. It worked great!

Ceiling nice and tight against the closet

And the upper kitchen cabinet too

Craig finished trimming along the edge for me.
I think he really wanted to play with my cute 12v Ryobi
cordless circular saw. It's a gem - I love it.

A coat of white exterior paint over the top of the ceiling/front.
Never hurts to seal it up!

And as viewed from the rear

The solid glued-up panel of white cedar strips proved to be too heavy.
Resorting to Plan C - cutting it into rails and stiles and making a panel door.

Cutting the mortices

Mortices done

Cutting tenons

Tenons done

And, dry fit - next to the totally trashed original door

Inside of door, panels installed. Rest of door will also be stained and poly'd.

Outside of door, painted panels installed.
Rest of door will be painted as well - 2 coats of primer and
2 coats of paint on the panels - so if the rails/stiles shrink, I won't have
an unpainted gap showing on the panels.

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National Serro Scotty Organization | Delton, Michigan 49046