Phasing a Long Restoration So Each Year Ends Usable
Written by Structural Repair Lead, Structural and Frame Lead, OCRV Center. Reviewed by Fleet Account Manager
In shortDraw every phase boundary at a dry, towable, lockable unit. Structure, then envelope, then systems, then interior. Cutting the line anywhere else means paying for the same access twice.
How do you split an RV restoration into phases?
Order the phases structure, envelope, systems, interior, and end each one with a unit that is water tight and safe to tow. Owners restoring older units bring them to our Yorba Linda floor one phase at a time, with a separate work order and date for each stage.
- A phase that ends with an open envelope is not a phase
- Structure first because it changes every dimension downstream
- Interior finishes last, after the unit has proven dry
- Each phase is its own work order, scope and deposit
- Phases
- FourStructure, envelope, systems, interior finish
- Boundary rule
- Dry, towable, lockableEvery phase ends there or the boundary is in the wrong place
- Structural labor
- $210 per hourFrame, subfloor, cage and skin work bills as body time
- Systems labor
- $260 per hourWiring, appliances, plumbing and generators
- Special order parts
- Full deposit at orderNon refundable once a part is placed
Last verified
Long projects fail on boundaries, not on budget. An owner with a 1978 shell and a sensible three year plan gets into trouble the moment a phase ends with the roof open, the wiring pulled and the unit sitting under a tarp for eight months. Everything that happens next costs more than it should, and some of it has to be done twice.
The rule that prevents it is simple to state and unpopular to hear: every phase has to end with a unit that is dry, safe to tow and able to be locked. That constraint decides where the lines go, and it is the reason the phase order below is not the order most owners would choose on their own.
The boundary rule, and why it governs everything
A unit that cannot shed water deteriorates while it waits. That is not a slogan, it is what we see arrive: shells that were opened for a subfloor job, left through a wet winter under plastic, and came back with damage in three places that had been fine. Plastic sheeting and a tarp are not a roof. The framing and the core absorb whatever gets past them, and the second phase then starts by undoing the first.
So the test for a phase boundary is physical. Can the unit sit outside for six months in this state without getting worse? Can it be towed to storage without stressing something that is half assembled? Can it be locked, so tools and copper are not an invitation? If the answer to any of those is no, the boundary is in the wrong place and the phase needs to be either shortened or extended until it is.
The four phase order
The sequence below moves from the parts of the unit that decide every dimension downstream to the parts that only decide how it feels. Owners frequently want to reverse phases two and three, because power and appliances are the fun part. That reversal is the single most expensive planning error in this whole category.
- Each phase gets its own written scope, its own photographs and its own delivery date
- Structural findings inside phase one routinely change the phase two scope, so phase two is not priced until phase one closes
- Systems are pulled and capped during phase one and two rather than reinstalled mid project
- Structure: frame rails, outriggers, subfloor, wall cage members, slide box squareness, axles and suspension mounts
- Envelope: roof deck and membrane or laminate, skin repair, windows and their returns, sealant, refinish
- Systems: shore power and house DC, converter or inverter, propane, plumbing, appliances, generator, roof air
- Interior finish: flooring, cabinetry, countertops, upholstery, lighting trim, final detail
Where owners draw the line in the wrong place
The most common bad boundary is refinishing before the windows are done. Paint goes on, then a window is replaced six months later, and the return has to be cut into a finished panel with a bead of sealant landing on new clear coat. A close second is new flooring installed before the core has been proven dry, which buries the evidence and guarantees that the next moisture reading is meaningless.
The third is buying appliances early because a sale price came along. A refrigerator that sits in a garage for two years is a refrigerator whose coverage period runs out before it is ever installed, fitted into a cabinet opening that may have changed dimension during structural work. We ask owners to hold systems purchases until the phase that installs them is scoped, and to keep receipts and model numbers in the project file either way.
Before you proceed
Do not order a special order part for a later phase early. Special order parts require a full deposit at order and that deposit does not come back if the scope changes underneath it.
How the money works across phases
Each phase is authorized on its own. Deposits follow the standard thresholds, so a phase over $2,000 takes half up front and a phase over $10,000 takes another quarter when parts land. Splitting a project into four work orders means four deposit conversations, which owners sometimes find annoying and which also means a bad surprise in phase one does not have your entire budget committed.
The other financial reality is that phase one prices are the least predictable. Frame and subfloor scope is discovered rather than estimated, because the damage is under the floor. We handle that with a diagnostic and teardown allowance at $285 per hour with a one hour minimum, then rewrite the scope from what is actually visible. Owners who plan a fixed number for phase one are usually planning around the wrong number.
Keeping a file that survives three years
A multi year project generates more documentation than any single repair, and it matters more, because the technician who closes phase four may not be the one who opened phase one. We keep the measurement record, the photographs at every teardown, the part numbers and the scope revisions in one file against the unit. Owners should keep a parallel copy, including receipts for anything they supply.
That file is also what protects value. On a vintage or custom unit, documented structural work is the difference between a restoration and a story. If the unit is ever insured on an agreed value basis, or presented to a buyer, the file is the evidence. We do not decide value, but we can hand you a record specific enough for somebody else to.
Appendix: questions and answers
- Can the unit stay at the shop between phases?
- No, and that is deliberate. Bay space is scheduled work space, so each phase ends with the unit going home or to storage. That constraint is exactly why the boundary rule exists: if the unit has to leave in a state it can survive outdoors, the phase has to be planned to reach that state.
- How long does a typical restoration phase take?
- Structural phases run longest because scope is discovered as flooring and skin come off, and two to five weeks of bay time is common on a full subfloor. Envelope phases are governed by parts and by booth scheduling. Systems and interior phases are more predictable, usually one to three weeks depending on how much cabinetry is involved.
- Will you install parts I bought myself during a phase?
- Often yes, with two conditions. The part has to be correct for the unit, verified before the phase is scheduled, and labor is quoted the same either way. What we will not do is build a scope around a part sitting in your garage that nobody has measured, because a mismatch discovered mid phase stops the whole work order.
- What if I only care about the interior and want to start there?
- Then we will scope an interior only job and say plainly what risk you are accepting. New cabinetry and flooring installed over an unproven subfloor is money placed on top of an unknown. If the structure later needs work, the interior comes back out. Some owners accept that knowingly for a unit they plan to sell soon.
Open a file on this repair
Tell us the vehicle, what happened and whether a claim is open. We will tell you what the scope looks like and what it takes to get you back on the road.
Or call (949) 799-3387
