Foretravel Motorhome Forums => Foretravel Tech Talk => Topic started by: WaltH on July 22, 2014, 01:31:41 pm
Title: Bulkhead issue - model years affected?
Post by: WaltH on July 22, 2014, 01:31:41 pm
I've read a little about the bulkhead issue of potential rusting on some FT coaches (a search on the term "bulkhead" turned up 489 posts - so I haven't read them all :) ), and I've seen one example in person.
Is this still a potential issue on FT coaches? If not, when did this stop being a possible problem. Are there particular models or model years that are more susceptible to this possibility? Does the length of the coach come into play at all? Thanks.
Title: Re: Bulkhead issue - model years affected?
Post by: Tim Fiedler on July 22, 2014, 02:08:13 pm
Walt. The issue is well vetted. Suggest you find time to read those posts, since you seem to be cautious and inquisitive. In general, it is not an issue, or relatively inexpensive to correct. If left too long damage can become extensive. A good pre-but will turn up any issues. Mine was addressed a few years for less than $1,000.
As you will see in his posts Don is now our resident bulkhead expert. :-)
Title: Re: Bulkhead issue - model years affected?
Post by: Dave M (RIP) on July 22, 2014, 02:49:45 pm
Have been told starting with the 2001 model, the issue has been either reduced or eliminated due to a new/differnet method of attaching the suspension/rear axle to the body. I do not know, just repeating what was told. We all know how reliable opinions & gossip is, why I say I do not know.
My 2001 is total clean most likely due to being a garage queen 11 months of the year. Used mostly short trips a week at a time. Not retired, just enjoy playing.
Title: Re: Bulkhead issue - model years affected?
Post by: WaltH on July 22, 2014, 03:05:32 pm
Walt. The issue is well vetted. Suggest you find time to read those posts, since you seem to be cautious and inquisitive. In general, it is not an issue, or relatively inexpensive to correct. If left too long damage can become extensive. A good pre-but will turn up any issues. Mine was addressed a few years for less than $1,000.
As you will see in his posts Don is now our resident bulkhead expert. :-)
I just read through one 11-page thread on this. I see, too, that this is - generally speaking - nowhere near as major a concern as the so-called "big three" issues that Tiffin motorhomes faced over a multi-model year period.
As for being cautious and inquisitive, I take that as a compliment since you didn't refer to me as a PITA. :D In some respects, I am anything but. I have wanted to "rush in" to coach ownership for some time as that will make me feel one step closer to my ultimate goal of full-timing. However, as FT is at the top of my short list of brands I want to consider, I want to make sure I have as much knowledge (i.e., ammunition) as this feeble brain can hold when it comes time to convince my wife. :)
Title: Re: Bulkhead issue - model years affected?
Post by: WaltH on July 22, 2014, 03:07:02 pm
Have been told starting with the 2001 model, the issue has been either reduced or eliminated due to a new/differnet method of attaching the suspension/rear axle to the body. I do not know, just repeating what was told. We all know how reliable opinions & gossip is, why I say I do not know.
My 2001 is total clean most likely due to being a garage queen 11 months of the year. Used mostly short trips a week at a time. Not retired, just enjoy playing.
If true, that would be good news from my standpoint as 2001 to maybe 2003 will be part of the model year range we will be able to consider when the time comes.
Title: Re: Bulkhead issue - model years affected?
Post by: WaltH on July 22, 2014, 03:35:58 pm
I read through Brett Wolfe's sticky on bulkhead repair and will admit to being confused about one thing. In that post, he states:
Quote
I used good quality Cobalt bits, progressing up one bit size at a time, using plenty of cutting oil and keeping the bit cool. Then, to access the "inside" to install the plate, washer and nut, I used a 1 3/8" hole saw to cut through the very thin fiberglass bottom of the coach. Hole was centered on the bolt left to right and the closest edge of the hole was approximately 3/4" in from the inboard edge of 1 1/2" beam. This allows access with a screwdriver to easily remove the foam core, exposing the beam and also access for the 9/16" wrench to tighten the nut. When locating the thru-bolts, use a magnet to locate the other beams in the fiberglass "floor" to the basement. Since you need access to install the plate, washer and nut, obviously, avoid areas with beams in the floor.
Having only seen one FT coach up close and in person, I am a little confused by this instruction. Is the fiberglass bottom actually accessed from underneath the coach, then? I'm sure this may be a stupid question, but I'd rather be stupid now when trying to understand the situation and the solution than stupid later as it were. (I don't think any of the photos I've seen on the subject show where this hole is cut, although I probably missed it somewhere.) Thanks.
Title: Re: Bulkhead issue - model years affected?
Post by: Tim Fiedler on July 22, 2014, 03:40:12 pm
You won't have to convince her once she sees one . Do it sooner rather than later.
Title: Re: Bulkhead issue - model years affected?
Post by: Tim Fiedler on July 22, 2014, 03:45:46 pm
Bottom of chassis has a fiberglass "pan" from front wheels to rear wheels
Title: Re: Bulkhead issue - model years affected?
Post by: John Haygarth on July 22, 2014, 03:47:38 pm
Walt- 2nd posting down in that search will bring up a letter giving you some idea of were they drill, I copied and pasted here Holes were cut with a 2" hole saw on a electric drill. Edge of hole is 2" from edge of angle iron. This will place edge of hole next to square tubing. fibreglass skin is very thin. beneath skin is plywood near passenger side edge and curb side, with remainder being foam. There are vertical square tubing which can be seen through the skin or found with a magnet. Nuts are on the inside. If holes are place correctly nuts are easiy accesable with wrench. Enough wood can be dug out with a chisel. foam comes out easily with a knife.
On the passenger side for approximately 2 ft. from the edge there appears to be an additional square tubing which will take longer bolts if you choose to place them there.
Having said this I had the initial repair done elsewhere, not FT. Recently after seeing this thread I decided to remove the covers and inspect the repair. The bolts were very rusted after only one year. I removed the old bolts and replaced them with 3/8" SS bolts, 6 in all. JohnH
Title: Re: Bulkhead issue - model years affected?
Post by: WaltH on July 22, 2014, 03:53:13 pm
Bottom of chassis has a fiberglass "pan" from front wheels to rear wheels
Okay, that helps. I'm sure it was stated somewhere, and I simply missed it. Thanks.
Title: Re: Bulkhead issue - model years affected?
Post by: wolfe10 on July 22, 2014, 03:59:45 pm
Yup, the "floor" of the basement is a one piece fiberglass sheet from back of front bulkhead to front of rear bulkhead. So, looking up from the ground, you will see a solid sheet of white fiberglass from just behind the front wheel to just in front of the rear wheel.
You drill just center (toward middle of coach) of the bolt location to access the inboard end of the bolt to install an oversized washer and nut.
Title: Re: Bulkhead issue - model years affected?
Post by: Tim Fiedler on July 22, 2014, 03:59:49 pm
You should really find one nearby to look at.....
Title: Re: Bulkhead issue - model years affected?
Post by: WaltH on July 22, 2014, 04:10:33 pm
Walt- 2nd posting down in that search will bring up a letter giving you some idea of were they drill, I copied and pasted here Holes were cut with a 2" hole saw on a electric drill. Edge of hole is 2" from edge of angle iron. This will place edge of hole next to square tubing. fibreglass skin is very thin. beneath skin is plywood near passenger side edge and curb side, with remainder being foam. There are vertical square tubing which can be seen through the skin or found with a magnet. Nuts are on the inside. If holes are place correctly nuts are easiy accesable with wrench. Enough wood can be dug out with a chisel. foam comes out easily with a knife.
On the passenger side for approximately 2 ft. from the edge there appears to be an additional square tubing which will take longer bolts if you choose to place them there.
Having said this I had the initial repair done elsewhere, not FT. Recently after seeing this thread I decided to remove the covers and inspect the repair. The bolts were very rusted after only one year. I removed the old bolts and replaced them with 3/8" SS bolts, 6 in all. JohnH
Thanks for the additional information. I went back to the search and tried to find - without success - the reference to this part of the procedure, so thanks for quoting it here.
Title: Re: Bulkhead issue - model years affected?
Post by: WaltH on July 22, 2014, 04:14:05 pm
I have seen one coach in person. That's how I first heard about the bulkhead and about where to look. Unfortunately, at the moment that seems to be the only FT coach nearby. However, another member of this forum has graciously offered a look at his coach when he passes through Boise after Labor Day. When that comes about, I'll be sure to take my wife so she can see for herself.