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Topic: Bulkhead issue - model years affected? (Read 663 times) previous topic - next topic

Bulkhead issue - model years affected?

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.
Walt Huntsman
Boise, Idaho
no Foretravel (yet)
2007 Alpenlite Voyager 31RE
2006 Ford F-350 DRW

Re: Bulkhead issue - model years affected?

Reply #1 –
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. :-)
Tim Fiedler    2025 LTV Unity MBL on Order
2000 Chevy Tracker 2 Door Convertible 4WD Now lifted 4.5"
1985 Citroen 2CV6 Charleston
Murphy Rebel on wheels with 175HP Titan
Cessna P337
1980 48' Westport MY (!/4 Share)

Re: Bulkhead issue - model years affected?

Reply #2 –
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.

Re: Bulkhead issue - model years affected?

Reply #3 –
Quote from: Tim Fiedler –
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. :)
Walt Huntsman
Boise, Idaho
no Foretravel (yet)
2007 Alpenlite Voyager 31RE
2006 Ford F-350 DRW

Re: Bulkhead issue - model years affected?

Reply #4 –
Quote from: Dave M –
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.
Walt Huntsman
Boise, Idaho
no Foretravel (yet)
2007 Alpenlite Voyager 31RE
2006 Ford F-350 DRW

Re: Bulkhead issue - model years affected?

Reply #5 –
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.
Walt Huntsman
Boise, Idaho
no Foretravel (yet)
2007 Alpenlite Voyager 31RE
2006 Ford F-350 DRW

Re: Bulkhead issue - model years affected?

Reply #6 –
You won't have to convince her once she sees one . Do it sooner rather than later.
Tim Fiedler    2025 LTV Unity MBL on Order
2000 Chevy Tracker 2 Door Convertible 4WD Now lifted 4.5"
1985 Citroen 2CV6 Charleston
Murphy Rebel on wheels with 175HP Titan
Cessna P337
1980 48' Westport MY (!/4 Share)

Re: Bulkhead issue - model years affected?

Reply #7 –
Bottom of chassis has a fiberglass "pan" from front wheels to rear wheels
Tim Fiedler    2025 LTV Unity MBL on Order
2000 Chevy Tracker 2 Door Convertible 4WD Now lifted 4.5"
1985 Citroen 2CV6 Charleston
Murphy Rebel on wheels with 175HP Titan
Cessna P337
1980 48' Westport MY (!/4 Share)

Re: Bulkhead issue - model years affected?

Reply #8 –
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
Coachless, now use aircraft. 2003 Ford Travelair TC280 class C. Super shape. Just for 1 yr .
1994 Ford E350 ClassC,total renovation inside and out. Now sold.
2000 U295  36' Cummins 350 c/w Banks Stinger, Resonator upgrade,Solar, LED lites.Residential fridge with slide out pantry. Build 5674. Sold
ex 92 GV 022C ored Cummins. Sold
ex 95 GV240 cat 3116. Sold
2017 Mini cooper s & 2016 land Rover LR2 HSE  LUX.
jhaygarth@aol.com    SKP #130098
treat everyone as you would like to be.

Re: Bulkhead issue - model years affected?

Reply #9 –
Quote from: Tim Fiedler –
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.
Walt Huntsman
Boise, Idaho
no Foretravel (yet)
2007 Alpenlite Voyager 31RE
2006 Ford F-350 DRW

Re: Bulkhead issue - model years affected?

Reply #10 –
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.
Brett Wolfe
EX: 1993 U240
Moderator, ForeForum 2001-
Moderator Diesel RV Club 2002-
Moderator, FMCA Forum 2009-2020
Chairman FMCA Technical Advisory Committee 2011-2020

Re: Bulkhead issue - model years affected?

Reply #11 –
You should really find one nearby to look at.....
Tim Fiedler    2025 LTV Unity MBL on Order
2000 Chevy Tracker 2 Door Convertible 4WD Now lifted 4.5"
1985 Citroen 2CV6 Charleston
Murphy Rebel on wheels with 175HP Titan
Cessna P337
1980 48' Westport MY (!/4 Share)

Re: Bulkhead issue - model years affected?

Reply #12 –
Quote from: John Haygarth –
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.
Walt Huntsman
Boise, Idaho
no Foretravel (yet)
2007 Alpenlite Voyager 31RE
2006 Ford F-350 DRW
 

Re: Bulkhead issue - model years affected?

Reply #13 –
Quote from: Tim Fiedler –
You should really find one nearby to look at.....
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.
Walt Huntsman
Boise, Idaho
no Foretravel (yet)
2007 Alpenlite Voyager 31RE
2006 Ford F-350 DRW