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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 #75 –
A couple of pics... fabricated some of the aluminum shelves with Angle Iron supports welded to the framing. The 3/16"X1.5" angle iron, along with the gussets, also beefs up the slightly thinned out original frame members creating a very strong rectangle. That will run from one edge go the utility compartment (front to back on both street side and curb side) to the other when it is finished ::)
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Don & Tys
1999 U270 3602 WTFE #5402
Xtreme Stage 1 w/Headlight, Step Conversion, etc.
2009 Honda Fit Sport with Navi
Freedom is NOT "just another word for nothing left to lose"... with apologies to Kris Kristofferson

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

Reply #76 –
Hmmm.  I'd rethink screwing that aluminum directly to steel, would insulate it somehow.  If you do, don't make the mistake of using stainless screws, galvanized is far less reactive.  Personally, I would tape it down with VHB or bed it in a caulk type adhesive with no fasteners.  Years of owning an alloy fab shop, building alloy boats, things like this give me pause.  That said, it's not a huge deal and you've really done a fine job of reconstruction. 
"Not so  long ago we were a nation of risk takers, riding five million pounds of  thrust straight into space."  Joe Gresh
Chuck Pearson
1996 U295
2018 Can Am X3 TurboRS

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

Reply #77 –
Thanks for the compliment Chuck...
I have given it some thought and research... while I wouldn't want to do this in a boat or marine environment, I don't believe that in my application it will be an issue in the life span of our Foretravel. A couple of points, the aluminum and the steel are both 3/16" thick, will be coated with Por-15 and the threads with Loctite (These plates are not designed to be easily removable).  Acouple of the aluminum plates are warped in one direction (I got them in the remanants pile: :D ), so I don't think the tape is a viable option for those. One thing I know, I am going to war against water intrusion into this area! Also, compared to the plywood sponges that were in this area before the rebuild, the aluminum plates will be less destructive to the steel framework. Another point that I mentioned previously in this thread is that Foretravel frequently joins Aluminum to steel in the coach, i.e., the auminum eztrusion that forms the sill along the bottom. Not to mention the aluminum superstructure joined to the steel side wall framing, and certainly even the Alcoa wheels held to the steel hubs by steel studs and nuts. One other small point, I will have rigid styrofoam insulation below the aluminum plates that should provide a bit more R-Value than the 1.5" of plywood previously there.
I am contemplating using a continuos sheet of 18gage stainless steel sheet in place of the FRP on the bottom of the compartment, or perhaps a much thinner gage (say 24) over FRP. I notice that many of the newer Foretravels and other hi-line coaches using stainless in that area these days... bad idea? I don't know if they are using FRP under the stainless, but I suspect so, and that the Stainless Steel is just a thin decoritive finish... well still a ways to go, back to work!

Quote from: Chuck Pearson –
Hmmm.  I'd rethink screwing that aluminum directly to steel, would insulate it somehow.  If you do, don't make the mistake of using stainless screws, galvanized is far less reactive.  Personally, I would tape it down with VHB or bed it in a caulk type adhesive with no fasteners.  Years of owning an alloy fab shop, building alloy boats, things like this give me pause.  That said, it's not a huge deal and you've really done a fine job of reconstruction.
The selected media item is not currently available.
Don & Tys
1999 U270 3602 WTFE #5402
Xtreme Stage 1 w/Headlight, Step Conversion, etc.
2009 Honda Fit Sport with Navi
Freedom is NOT "just another word for nothing left to lose"... with apologies to Kris Kristofferson

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

Reply #78 –
Don, et.al.,
Thank you all for a very informational and inspirational thread.  I enjoy following this.  I just hope I don't need this information.  But I now feel compelled to do a really careful inspection.

Bob Thomas
Sacramento, CA
Present:  1997 U320 '40
Previous: 1997 U295 '36
Bluegrass fan, and festival emcee

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

Reply #79 –
Your welcome! I hope your inspection reveals nothing but a sound bulkhead joint... Sorry for the delay in my reply, I guess I missed this post somehow.
Don
Quote from: Bob Thomas –
Don, et.al.,
Thank you all for a very informational and inspirational thread.  I enjoy following this.  I just hope I don't need this information.  But I now feel compelled to do a really careful inspection.
The selected media item is not currently available.
Don & Tys
1999 U270 3602 WTFE #5402
Xtreme Stage 1 w/Headlight, Step Conversion, etc.
2009 Honda Fit Sport with Navi
Freedom is NOT "just another word for nothing left to lose"... with apologies to Kris Kristofferson

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

Reply #80 –
The actual reconstruction is now close to finished and I thought I would post picture or two to update this thread (because I know that there are many out there holding their breath waiting for the next installment ;D
Almost ready to do the POR-15 coating... just some clean up from underneath to do and then I will open up the bulkhead joint so I can treat the space between. I will have more to say about how that is accomplished because a compromised bulkhead joint also causes some collateral damage similar to what is described in the "Calamity Jane strikes again" thread, and I have plans to reinforce the framing that attaches the suspension carriage to the bulkhead angle iron. Here are a few before and after pictures of the framing work I have done. As I said, it is mostly complete now. Unfortunately, I don't have any equivalent single before picture because I didn't set out to rebuild the whole thing from the start... just gradually came to the awareness that I wouldn't feel happy about the integrity of the utility compartment framing without going all the way.
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Don & Tys
1999 U270 3602 WTFE #5402
Xtreme Stage 1 w/Headlight, Step Conversion, etc.
2009 Honda Fit Sport with Navi
Freedom is NOT "just another word for nothing left to lose"... with apologies to Kris Kristofferson

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

Reply #81 –
As is so typical you start out to replace a missing screw and end up rebuilding the whole coach!  I too, can attest to the downside of water soaked wood against steel.  Lucky for me my repairs are quite minor compared to yours.  I ended up using wood hardener to permanently seal the wood that I replaced.
John Cooper
'91 GV 36'
Oshkosh chassis
Cat 3208T 300HP

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

Reply #82 –
LOL! Or maybe COL... wondering if you made that analogy from just reading this thread or if you were referencing my latest hijinks in the thread about the Fiberglass fuel tank cover on Unicoach covers on the unicoaches where I discovered more basement mysteries... I guess I should have posted that stuff in this thread since it really is just a continuation of same, though so far no welding has been involved!
Don
Quote from: John Cooper –
As is so typical you start out to replace a missing screw and end up rebuilding the whole coach!  I too, can attest to the downside of water soaked wood against steel.  Lucky for me my repairs are quite minor compared to yours.  I ended up using wood hardener to permanently seal the wood that I replaced.
The selected media item is not currently available.
Don & Tys
1999 U270 3602 WTFE #5402
Xtreme Stage 1 w/Headlight, Step Conversion, etc.
2009 Honda Fit Sport with Navi
Freedom is NOT "just another word for nothing left to lose"... with apologies to Kris Kristofferson

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

Reply #83 –
Don,

Personal experience with "old" stuff, especially my Prowler TT (the reason I now own a Foretravel), and the mention of no pictures in the beginning.  I have not seen your thread yet.
John Cooper
'91 GV 36'
Oshkosh chassis
Cat 3208T 300HP

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

Reply #84 –
Such has been my experience with old stuff as well. Irrationally, I had hoped this one would be different just his once! :o
Quote from: John Cooper –
Don,

Personal experience with "old" stuff, especially my Prowler TT (the reason I now own a Foretravel), and the mention of no pictures in the beginning.  I have not seen your thread yet.
The selected media item is not currently available.
Don & Tys
1999 U270 3602 WTFE #5402
Xtreme Stage 1 w/Headlight, Step Conversion, etc.
2009 Honda Fit Sport with Navi
Freedom is NOT "just another word for nothing left to lose"... with apologies to Kris Kristofferson