Constructing the Airstream

      The earliest designs of the Clipper from the 1930s already boast of the most advanced heat insulation and ventilation systems. In addition to electric lights, Airstreams even came with their own dry-ice air conditioning system. 

      The current Clipper design uses two aluminum shells with a layer of insulation sandwiched in between. The layer of insulation consists of a 2-inch temperature resistant mattress of aerocore fiberglass that's impervious to flame, vermin, water, and settling. This allows for cool temperatures in the summer, and warmer temperatures in the winter. 

Structural member of the trailer body being wired

                                                          Fitting the insulation into the walls

      The central door of the Clipper has a part that can be opened to turn the door into a screen for added ventilation. Instead of nails and screws which might dislodge overtime from excessive road wear, each Clipper is constructed with thousands of rivets. Each rivet alone requires two skilled mechanics to drive into the Clipper's body. One can only imagine how much time and effort was required for the completion of each trailer. 

In essence, every square inch of the Airstream Clipper was designed for a functional purpose.

"Let's not make any changes - let's make only improvements"

Over the years, Wally Byam adopted this phrase as the motto for his Airstream Company. As demonstrated by the iconic silver aluminum of the Clipper's exterior shell, Wally made changes to his designs only when he found it absolutely beneficial to the function of the trailer. Consequently, the aesthetics of the trailer underwent minimal changes over the course of its lifetime. Five major body changes later, the aluminum shell of the first 1936 Clipper is still on the roads.

Just as Wally Byam wished, the company made nothing but improvements. Wally's experience in aircraft during the war led to the development of the dura-torque axle running gear. Its installation in the trailer eliminated 148 extraneous parts, absorbed bumps, and reduced slipping and side-sway. Additionally, it increased ground clearance by 8 inches and minimized the need to lubricate the axle assembly. Before 1957, the Clipper had 13 metal sections on either ends. In more recent designs, the sections were widened, reducing their number to just 7. By flattening the underside of the belly, Wally also reduced the Clipper's wind resistance. He also installed an 18 by 40 inch window at the back of the trailer in case the side door was jammed.

                                                      1957 Airstream Clipper with the rear-window


Throughout his career, Wally Byam scoured the world for new inventions and innovations that would improve the functionality and livability of the Airstream Clipper. Things as small as door hinges and as large as toilets, hot water heaters, and porcelain sinks were all on Wally's agenda. If Wally were still alive, much of his time would undoubtedly be spent in the aisles of Home Depot, searching for any small piece that might improve the Airstream. After a visit to Europe, Wally Byam found a heating system that provided radiant heat without taking up much space. He borrowed the idea to create his own heating system, which he later renamed the Byam Burner. In France, he found a compact refrigerator which replaced the inefficient ice-boxes that were once found in the early Clippers. Hot water systems and steam-pressured flush toilets are just a few of the other things that Wally brought to the Airstream over the years.

"Let's not make any changes -  let's make only improvements."

Tidbit #3

      The Airstream's aluminum exterior and design of its shape is based on the airplane fuselage and the rounded corners increases gas mileage and cuts drag by 20 percent compared to the standard square trailers.

Sources:

"Fast Facts." Airstream, Inc. Airstream, Inc., n.d. Web. 14 Nov 2012. <http://www.airstream.com/comp

      any/fast-facts/>

Hawley Bowlus

      William Hawley Bowlus, born 8 May, 1896, was a designer, engineer and builder of aircraft and recreational vehicles in the 1930s and '40s. Prior to his work on travel trailers, he was the Superintendent of Construction on Charles Lindbergh's aircraft, the Spirit of St. Louis. He also designed and constructed the innovative but unsuccessful XCG-16A experimental military glider ordered by the U.S. Army Air Corps in 1943.

Charles Lindbergh in front of his plane, Spirit of St. Louis

"Fathers of Aircraft Maintenance." Amtausa. http://www.amtausa.com/fam.html (accessed December 10, 2012).

Sources:

"History." Airstream, Inc. Airstream, Inc., n.d. Web. 14 Nov 2012. <http://www.airstream.com/company

      /history/>

Airstream Purists

      To many Airstream enthusiasts, the Clipper is known as 'Granddad'. Contrary to what one might assume, this name was coined out of respect and adoration for the vehicle, rather than ridicule and mockery over its age. After all, the Airstream has only undergone five major body changes since 1936, and none of these alterations had any affect on the iconic aluminum shell of the Airstream trailer. Over the years, the Airstream designs have been changed to accommodate larger interior spaces and improve ease of towability, but the reputable aluminum casing that surrounds the Airstream's exterior is just as lustrous and round now as its first model. It's no wonder, then, that people have developed a particular fondness for the iconic Airstream look. In fact, any models that deviate from these aesthetics are heavily condemned by the purist community.

Airstream Clipper '36

      In 1989, an Airstream Land Yacht was released in a beige colour with a sawed-off, square-ish front. Not surprisingly, the trailer was quickly dubbed the 'Squarestream', which -- unlike the 'Granddad' -- was not at all endearing. To say the least, it wasn't one of their most popular products.

                                                                     The 'SquareStream'

      Later on, Airstream released a trailer named 'Integrity' with a fifth wheel attached to an additional axel. Anyone who was unfortunate enough to be seen traveling in this trailer was dubbed the 'Tupperware Trailer'.

Integrity, a.k.a. 'Tupperware Trailer'

Sources:

Burkhart, Bryan, and David Hunt. Airstream: The History of the Land Yacht. San Francisco: Chronicle, 2000. Print.

The 1936 Airstream Clipper

 Streamlined Car

      The streamline style of the 1930s was a result of the Art Deco style that originated in Paris in the 20s.  This sleek, simple modern look was used widely in the designs of cars, furniture, and of course the iconic Airstream Clipper trailer.  William Hawley Bowlus was one of the first builders of the streamlined trailers.  He was the first to produced the aluminum Road Chief trailer that was shaped like an airplane fuselage.  

Road Chief 

      After Bowlus' company went bankrupt in 1936 Byam purchased some of his equipment and hired a number of his employees and redesigned Bowlus' trailer into the Airstream Clipper.  Byam installed roll-up windows and moved the door of the trailer to the side which allowed for the front edges to disappear.  He also moved the chassis between the wheels and raised the covers for a larger interior.  Today only a handful of Clippers remain but the look and feel of past and current Airstreams all originated from the original design.

Airstream Clipper

Sources:

Lopez Cotelo, B. "Airstream Clipper." Tectonica Blog, 21 January 2010. Web. 5 Nov 2012. <http://tectonicablog
      .com/?p=4470>.
Strongman, Tom. "1936 Airstream Clipper." Tom Strongman's Auto Ink, 17 September 2012. Web. 9 Dec. 2012. 
      <http://tomstrongman.com/1936-airstream-clipper-3/>.

Light and Strong

Light enough to be towed by a bicycle

      Airstream manufacturing borrowed much of its processes from aircraft design which gave the trailers a very high strength weight ratio.  The interior rib is built out of aluminum as a support frame for the exterior skin, a technique still used today.  

 Airstream's framing system

      The trailers also use monocoque construction, where the shell of the vehicle carries most of the weight and stress.  From Greek mono for one and French coque meaning shell, monocoque construction is one in that the structural load of the object is supported by the external material rather than the internal frame. For example, a typical automobile is not a perfect monocoque construction and uses a series of tubes and bulkheads to provide support while the external body adds little strength or support. In monocoque construction, the body and chassis form a single unit.

Airstream's exterior aluminium shell

Strong but load bearing

      The ridgid yet light weight aluminum skin is then riveted onto the interior frame to create the shell of the Airstream trailer.  The details and number of panels has changed over the years but the basic design has not changed much from the original 1936 Airstream Clipper.

Sources:

"Airstream Style Through the Years." Boston Globe. Boston Globe, n.d. Web. 14 Nov 2012. <http://www.boston
      .com/yourlife/gallery/071207_airstream/>

Hawley Bowlus' Road Chief

Hawley Bowlus's "Road Chief", the original riveted aluminum trailer. The company was purchased by Byam and later redesigned into the original Clipper by making minor modifications such as moving the door from the back to the middle.