Chassis construction photos from Don and welding on your FT

Topic: Chassis construction photos from Don and welding on your FT (Read 5498 times) previous topic - next topic

Re: Chassis construction photos from Don and welding on your FT

Reply #50 – February 24, 2012, 09:57:16 pm

Awesome! So when should I schedule to drop mine off?

Re: Chassis construction photos from Don and welding on your FT

Reply #51 – February 24, 2012, 10:12:09 pm

Don, congratulations on a first class job you are doing. I have been in steel fabrication for many years earlier on and that is a nice job. Please make a file of the job as you proceeded and with photos as you whent and let barry include it in the Mods section of his FT website as that would be great info for future people (should they ever consider doing what you have almost done).
You may get a call from FT to work in their shop!!!!
John haygarth

Re: Chassis construction photos from Don and welding on your FT

Reply #52 – February 25, 2012, 12:43:59 am

Great job... breathtaking, in fact. I'm glad you're doing it and documenting it so I know that it can be done. I don't think I would have even considered it before seeing what you've done.

Thanks,
Craig

Re: Chassis construction photos from Don and welding on your FT

Reply #53 – February 25, 2012, 01:23:43 am

Thanks for the nice comments guys... every little bit of encouragement helps! I do plan on organizing my photos with some commentarty when I get the chance and put it in an album of some kind. I hope that it will be of use to those who find themselves in similar situations. This forum has been a source of great information and inspiration! Thanks to all who have generously shared their knowledge. I am looking forward to contributing a few tidbits of hardwon wisdom myself... More later! Good night all!
Don

Re: Chassis construction photos from Don and welding on your FT

Reply #54 – February 25, 2012, 08:21:38 pm

Looks excellent Don. Very nice work.

It feels good when you can see the plan coming together.

Steve

Re: Chassis construction photos from Don and welding on your FT

Reply #55 – February 26, 2012, 01:05:26 am

Thanks Steve!

It sure does feel good to be in the phase of the project where the progress is more noticeable, especially as opposed to the demolition phase when you aren't even sure how far to take it. At some point it felt like I was on a trajectory to demo the entire basement, since I originally was just going to do the standard bulkhead fix. Now I am glad I explored further because now I know the coach will be strong down there, not to mention all that I have learned while doing this project. I will have much to write about the subject, but that will have to wait awhile...
Don
P.S.here are a few more pics of some of today's progress. The previous set was the street side and this is the curb side, except the last pic which is an action shot

. On this side, I was able to leave the outside angle iron in place and I cut out the outermost 1&1/2" longitudinal square tube which was originally 16 gauge and thinned out by contact with the soaked plywood. I replaced it with new 13 gauge. That is what is in the pictures. I welded a nut to the square tubing for the outermost bolt on both sides. This nut is inside the outermost square tube on both sides. I am also using caged weld nuts where clearance allows on all the rest of the bulkhead bolts. There are a couple of places where I welded unistrut clip nuts. This will allow removal and replacement of all of the bulkhead bolts in the future without needing a wrench on the back side or a hole in the fiberglass to access them. The caged weld nuts are nice because they are easier to get started without risking cross threading.

Don

Quote from: Merle Hench – February 25, 2012, 08:21:38 pm

Looks excellent Don. Very nice work.

It feels good when you can see the plan coming together.

Steve

Re: Chassis construction photos from Don and welding on your FT

Reply #56 – March 28, 2012, 01:05:23 pm

Still progressing... Slowly, but surely! Here is a few more current pics...

Re: Chassis construction photos from Don and welding on your FT

Reply #57 – March 28, 2012, 01:12:22 pm

I am thinking that my little $99 wire-feed welder I bought from Harbor Freight might not be up to that kind of job.

Frankly, until I saw what you're doing, I would not have believed that it would be possible to completely rebuild these portions of a motorhome. I wonder if the Unicoach/Unihome construction methods are the only ones that you could do this sort of work on.

As usual, awesome! Just awesome!!!

Craig

Re: Chassis construction photos from Don and welding on your FT

Reply #58 – March 28, 2012, 01:20:09 pm

Beautiful work-- almost a shame to cover it up.

Brett

Re: Chassis construction photos from Don and welding on your FT

Reply #59 – March 28, 2012, 01:27:37 pm

Dang!!! That's A+ work as my dear, departed father-in-law would say, as a RIP high school shop teacher, now in heaven doing the greatest camping trip of all.
Peter

Re: Chassis construction photos from Don and welding on your FT

Reply #60 – March 28, 2012, 02:34:31 pm

Wow. You effort is much appreciated by an ex shipfitter and welder

Now, that I see how you do this all I need is a welder, someplace to do it, about $10,000 more in tools, a couple of lifts.... never mind - I couldn't do that!

Re: Chassis construction photos from Don and welding on your FT

Reply #61 – March 28, 2012, 04:59:26 pm

Thanks Guys! Brett, I briefly considered a transparent cover.... not for vanities sake, just so you could see if there was any moisture and rust creeping back in. Unfortuantely, all such material that I know of is somewhat brittle, and there for not suitable. If there was such a material one could use for the bottom skin, structural function not widthstanding, it would be a sure way to know what was going on down there!
Don

Re: Chassis construction photos from Don and welding on your FT

Reply #62 – March 28, 2012, 05:06:38 pm

Hi Don,
I agree with Brett. That work is just to nice to cover. Thanks for letting us follow along.
Raymond

Re: Chassis construction photos from Don and welding on your FT

Reply #63 – March 28, 2012, 05:35:51 pm

Quote from: acousticart – March 28, 2012, 04:59:26 pm

Thanks Guys! Brett, I briefly considered a transparent cover.... not for vanities sake, just so you could see if there was any moisture and rust creeping back in. Unfortuantely, all such material that I know of is somewhat brittle, and there for not suitable. If there was such a material one could use for the bottom skin, structural function not widthstanding, it would be a sure way to know what was going on down there!
Don

Don,
All it takes is lots of money. I'm sure there are automotive aftermarket companies that bullet-proof cars (mostly Suburbans, Rolls Royce, Cadillac and the like) that utilize advanced materials you can see through that can withstand the rigors.

Oh Yeah!

Re: Chassis construction photos from Don and welding on your FT

Reply #64 – March 28, 2012, 05:45:01 pm

Quote from: acousticart – March 28, 2012, 04:59:26 pm

Thanks Guys! Brett, I briefly considered a transparent cover.... not for vanities sake, just so you could see if there was any moisture and rust creeping back in. Unfortuantely, all such material that I know of is somewhat brittle, and there for not suitable. If there was such a material one could use for the bottom skin, structural function not widthstanding, it would be a sure way to know what was going on down there!

You mean Transparent Aluminum?

Star Trek really IS a good guide to the future... Scientists now able to produce

Live long and prosper, Don!

Michelle

Re: Chassis construction photos from Don and welding on your FT

Reply #65 – March 28, 2012, 11:54:12 pm

What about inspection plates such as are on airplanes? Well at least 40 years or so ago when I was a student pilot. From other posts that might not be necessary, as the bulkhead issue does not seem to be universal, as many owners have never experienced problems.

Re: Chassis construction photos from Don and welding on your FT

Reply #66 – March 29, 2012, 12:13:24 am

I agree, no reason to ever have to go back and inspect the bulkhead UNLESS he decide to let a water leak in the wet bay go unchecked for a long time or drive it through salt and then park it for months at a time. Since he will not do those kind of things, the only reason I hate to see him cover it up is the work of art he is creating.

Very rare to see bulkhead failure without long-term causes, and then they fail one bolt at a time. Just not a big deal unless just totally ignored.

Brett

Re: Chassis construction photos from Don and welding on your FT

Reply #67 – March 29, 2012, 10:38:03 am

You could just drill a 3/4" inch hole between the existing bolts and then use a digital inspection camera probe to take a look inside. They are available stand alone or probes that plug into a USB port on a Mac or PC laptop. They have 7 to 10MM diameter heads with LEDs so they supply their own light for the job. See at: inspection camera digital | eBay

Not all will work on all three computer operating systems so check the fine print before ordering. Mine only cost $50 delivered and plugs into my Mac laptop.

Naturally, you would want to have a plug for the hole. I almost have my service pit done so will be installing a new set of Hollo-Bolts between the OEM bolts. Will photo the job and post in the next couple of months.

Pierce

Re: Chassis construction photos from Don and welding on your FT

Reply #68 – March 29, 2012, 11:55:18 am

Transparent Aluminum, that's the ticket! So far, I haven't been able to source transparent aluminum in large enough sheets, but I will keep looking... LOL! Seriously though, I am not worried about it because I know that I will be vigilant about water leaks and moisture intrusion of any kind. Every penetration into the framework will be be sealed and all seams caulked with the best materials available. And then there is a fact that all the steel down there, including the sheet metal bulkhead will be coated with Por-15. The idea that it would be nice to put a transparent skin over it was just one of many that I briefly considered and discarded as I stared down at the exposed rusty metal in front of me, too tired after a long day of working to move and start putting everything away...
Pierce, I do have an inspection Camera and found it very useful when I was trying to route the washer drain pan tubing down alongside the water heater...
Don

Re: Chassis construction photos from Don and welding on your FT

Reply #69 – March 29, 2012, 12:35:01 pm

Don, great work and I was just wondering if you have considered using cold galvanizing paint for the steel coating or a 2 part commercial epoxy paint that is used for bridge construction?
John H

Re: Chassis construction photos from Don and welding on your FT

Reply #70 – March 29, 2012, 12:49:28 pm

Nope, not familiar with those... Anyway, I have already invested a fair amount of money in the Por-15 product line. I feel confident that it will do the job as well as it can be done. I did a few test pieces and it has performed well being left out in the rain and elements over the course of a few months.
Don

Quote from: John Haygarth – March 29, 2012, 12:35:01 pm

Don, great work and I was just wondering if you have considered using cold galvanizing paint for the steel coating or a 2 part commercial epoxy paint that is used for bridge construction?
John H

Re: Chassis construction photos from Don and welding on your FT

Reply #71 – March 29, 2012, 12:59:03 pm

Don's work is extensive and meticulous but what sorts of options are there for those of us who have some rust (and maybe a little scale) but not enough to warrant a complete rebuild? There are some products (mostly with tannin) that claim to "convert" rust and are paintable; I used one on a wheelchair lift before my knee surgery and it seemed to be very effective. I simply wire-brushed the rusty spots, applied the "converter" which served as a primer when dry and then painted the entire assembly with black rustoleum.

I have planned to do the same thing with the steel support structure around the generator on the U225. It's rusty with some scale but nothing that looks serious enough to require re-welding. Even though I'd re-weld it at the drop of a hat if I thought it was necessary; mostly because I love to weld... especially with my new auto-darkening helmet and the wire-feed.

Anyone have any alternative suggestions?

Craig

Re: Chassis construction photos from Don and welding on your FT

Reply #72 – March 29, 2012, 01:34:17 pm

Craig,

Those auto darkening helmets are great aren't they? How can you go wrong for $50 or less?

Would suggest drilling a hole in any suspect tubing and injecting several ounces of boiled linseed oil in each large rectangular/square tube, less in the small ones. It will climb up the walls and coat all interior surfaces. Stay away from the new synthetics as they don't work as well in the real world as their claims would have you believe.

Pierce

Re: Chassis construction photos from Don and welding on your FT

Reply #73 – March 29, 2012, 02:21:23 pm

I added boiled linseed oil to some tubing and it does wick its way around... However, I would do any welding you want to do first, or it can create a bit of excitement! Don't ask me how I know that

Don

Quote from: Pierce & Gaylie Stewart – March 29, 2012, 01:34:17 pm

Craig,

Those auto darkening helmets are great aren't they? How can you go wrong for $50 or less?

Would suggest drilling a hole in any suspect tubing and injecting several ounces of boiled linseed oil in each large rectangular/square tube, less in the small ones. It will climb up the walls and coat all interior surfaces. Stay away from the new synthetics as they don't work as well in the real world as their claims would have you believe.

Pierce

Re: Chassis construction photos from Don and welding on your FT

Reply #74 – March 29, 2012, 03:25:52 pm

Quote from: acousticart – March 29, 2012, 02:21:23 pm

I added boiled linseed oil to some tubing and it does wick its way around... However, I would do any welding you want to do first, or it can create a bit of excitement! Don't ask me how I know that

Don... I scared the cat by bursting out laughing at your comment. LOL. I'll keep it in mind.

Pierce... yes those helmets are great. One of my problems stick welding was that by the time I got my helmet down my hand had jerked and moved. The auto-dark feature makes it a piece of cake. And they look sooooooo cool!!!

I think that, unless someone comes up with a super idea, I'll stick with the "brush scale off, hit with the coverter and paint" method that worked for me before.

I have to find something to weld on though... now.

Craig

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