A Can of Worms

This isn't exactly "After", but a temporary set-up until we're ready 

to install the new breaker box/ 12V fuse panel.

Worms! They seem so innocent, going about the business of amending soil. But just wait until you open a can of them.

Used and vintage travel trailers can be the very epitome of a “can of worms.” You may think you’re starting with a relatively simple project on your punch list. Say, replacing the exterior traffic lights. Easy-peasy! Should only take a few days to get them all completed_.

One by one, all the old lights are gradually changed out for new, fancy LEDs. You think you’re almost finished and ready to move on to the next project. Hook up the tow vehicle to test your work. What the…? Everything seems to start off OK, then all of a sudden clearance lights are on when they shouldn’t be, or turn signals are not blinking when they should. Step on the brakes. All the exterior lights come on….that can’t be right. Even the license plate light blinks, though it should only come on with the headlights. The only lights not coming on at all are the back-ups. Morris Code can be seen from every angle by tapping the brakes. ZAP! One of the fuses in the vehicle’s tow package has blown.

Folks, when it comes to the various mechanicals that make your RV a cozy traveling home, nothing is more aggravating than electrical. (May change our opinion later, but there will be interior electrical changes made too.) There are three separate electrical systems which run appliances, lights and outside safety signals; 120V - similar to residential and runs on shore power or generators, and 12V which uses batteries (either from your tow vehicle or from the RV).

Anyone who has a basic understanding of these systems may feel they can comfortably renovate a travel trailer. Be honest about your ability and patience before committing to such a project. It may take more than one try to get something working properly. Also, can your budget handle it? In the effort to make things work, you may find you purchased items you didn’t need in the first place, you have to purchase additional materials, or buy replacements for the replacements because something got fried. The motto of many RV restoration/renovation enthusiasts is, “We do it right because we did it more than once.”

If you need expert help, it may be in your best interest and safety to have a certified RV repair technician assist you. To find a qualified technician we would recommend getting acquainted with other RV owners in your area, and through RV forums. Be prepared though. It could take anywhere from a couple of weeks to a month or more before a shop has an opening. Time of year can make a big difference in RV repair availability, and some shops are busy year round. It is a safe bet that even the most ultimate DIYers have used, or know of someone who has used local RV service centers at some point. Seek their council before you decide to work with a repair shop. Like many businesses, customer satisfaction varies greatly.

If, after you have weighed all the pros and cons, and still want to take on a project, we have a bit of advice. Friends or relatives may be able to help sort some electrical difficulties, but don’t be too dependent on their assistance. We have a friend who is a retired master electrician. He possesses an encyclopedic knowledge of residential electrical and doesn’t mind trouble-shooting with us, but he is the first to say 12 volt electrical is beyond his scope. Kristal’s dad has many years of experience with various utility trailers and a couple of RVs. He thinks trailer wiring is the devil’s work. RV owners’ forums are great for advice, but there may be differences of opinion. So, do your own research, weed through what others have done and tried (learn from their mistakes), and be prepared to try different things. Don’t be afraid to ask questions on the forums and be a part of lively discussions. Lastly, household wiring must meet specific codes, and so does wiring for the RV industry. Just like household renovation, sometimes things must be updated to code. Be prepared and flexible.

Now wait a minute, we can hear some say. “I thought you checked all this stuff before you bought your trailer.” Well, yes, we examined as much as we could when we first looked at it. But someone was living in it at the time, and even if they weren’t, a buyer can’t reasonably expect to dismantle something before it belongs to them. Since shore power and a battery were available, it was possible to turn on lights and run the air conditioner. We noticed some of the exterior signal lights needed replacement. However, there was nothing to indicate there were any major problems with any of these lights. When we first saw our Airstream it was in a backyard. Though there was alley access, it wasn’t practical to get our Expedition in there to test the signals. If we had to do it over again, we would have purchased a trailer tester (see below.), before shopping for a vintage travel trailer. Since our trailer was closed up, mostly intact, and generally well-cared for when we looked at it, the best we could do was cross our fingers and make a leap of faith, knowing full well there were likely to be some unexpected surprises. (Comes with the territory, especially if you’re a newbie.)

This is the tester we now have for the signal lights. The one we purchased is a 7-way blade plug tester. Be sure to purchase the correct one for your application (7-way blade or pin, 6-way, 5-way or 4-way). This tester has a setting for each of the lights, making it easier to find a problem child. It also allows us to check all of the exterior lights without having to hook up the tow vehicle. It doesn't come with a battery. We highly recommend purchasing a sealed AGM (doesn’t need maintenance), but be prepared to pay as much for it as the trailer tester itself.

This is the original 12V fuse panel with wiring modified by the PO.

Some wires, such as the the old breakaway switch were impossible to find.

Our trailer did come with a service manual and quite a few notes from the previous owner (PO). They’ve been both a blessing and a curse, especially when we discovered some substantial wiring changes were made at the front of the trailer and not really documented. We were aware from the beginning that the PO had removed the gaucho couch, necessitating relocation of the converter/charger and one 12V battery to the A-frame. (There were oringinally 2 batteries.) During the testing of our signal lights, we became concerned the trailer’s old 7-way harness wire may have a short which was causing our problems with the signals. In which case, the new plug we installed wasn’t going to help. Replacing the cord required removing the metal box holding the old converter & battery, opening up the bottom front of the trailer, and removing the interior front panel that covered the wires & 12V fuse box inside. There was more than a little bit of cursing. The converter box was a bastard to remove, and the wiring didn’t resemble anything in the Airstream service manual or any online diagrams.

This is the A-frame after being repainted and the new electric jack was installed.

The small black box mounted on the frame behind the jack contains

the excess wires from the new breakaway switch and jack.

We decided to put it in the box for protection from weather & road dirt.

Since the trailer was open anyway, it seemed like a good time to clean up and repaint the A-frame, and install the new electric jack & break-away switch. After the hours to complete those tasks, along with the time it took to trace old wires and make sure the new 7-way hitch cord was properly connected, it was our friend’s opinion that the relays we added to the trailer turn signals might be causing some of the issues we were still having with the exterior lights. We were at the point where there was nothing else left to try, so the turn signals were opened up again to remove them. Our friend’s hunch proved correct. Without the resistors, the traffic lights passed all their tests with flying colors.

So, was it necessary to do the A-frame work? Yes, it was. These tasks were already on the punch list anyway. As far as the resistors are concerned, it is a bit annoying to discover we didn’t need them. It was our decision to include them, since we didn’t know if our older tow vehicle would recognize the LED signals. The resistors didn’t cost more than a few dollars each. Still, time matters too. Just like home improvement, you may as well figure RV renovation is going to take you three times longer than you thought and possibly double the initial cost.

If you want to see additional pictures of the A-frame work, including before pics with the old converter box, they can be found on the Airstream forum where we're known as Starstream. Make inquiries here in the comments, and we'll let you know what threads to look at.