Rebuilding Crashed 1995 U295

Topic: Rebuilding Crashed 1995 U295 (Read 6313 times) previous topic - next topic

Rebuilding Crashed 1995 U295

June 10, 2021, 11:20:05 pm

Well the time has come to start my rebuild thread. This will be to log all the adventures with the new to us FT. Tonight was day one and the first time I have worked on anything on the new coach.

Today was an exciting day. I received my Porta-Power hydraulic set I ordered and my son and I jumped into trying it out. We figured out a couple of solid locations to press from and we moved some things around but quickly realized that the stair frame just needed to be removed entirely.

The sawzall came out and 3 cuts later the stair frame fell out. Not a single bolt was left intact from the accident which made things really easy to get it out. Just one bolt or screw in some back corner would have turned that into a much longer project. I did have to disconnect the airlines and wires to the step air solenoids then out it came. It is in pretty rough shape. Honestly not sure if I am going to try to rebuild the factory step. I have to think about it.

To end the night we rigged the ram into the door opening and spread it apart in a few spots. It started to line things up a bit but the warped door will need to come off to get the frame right. The door itself is going to be the most challenging part of the project for sure. We spent a few minutes looking at it closely and it is a very very well made door, but it is going to take some work to get it flat again. I think getting it removed and on the workbench will be the first step, then go from there.

There still is hope I could find a door as I have not called more than Visones to look for a possible used one.

Re: Rebuilding Crashed 1995 U295

Reply #1 – June 11, 2021, 12:01:57 am

Yikes! What happened?

Re: Rebuilding Crashed 1995 U295

Reply #2 – June 11, 2021, 07:03:10 am

I left out a bit of backstory, sorry about that! This is from a post on another site I made the day we bought it a few weeks ago. The pictures are of before and after damage occurred.

My wife and I made kind of a crazy decision out of the blue today. A 1995 Foretravel U295 came up for sale locally. It was 10 mins from my house and I had to go look with the DW. They guy selling it is in a bad situation where he bought it just last fall. He almost immediately accidentally left the parking brake off and it went rolling into another truck and damaged the front door and steps.

I went and looked it over and the coach is clean really nice condition coach. Engine compartment and everything I looked over is in really great condition. Needs tires, air bags, and front end repairs. We made a deal and we are picking it up tomorrow. I know I am able to do the work but am I crazy??

The idea is selling our current 1994 HR Navigator (See my rebuild thread here)) and making this our new coach. Biggest reason being it seems like it is in better shape to start with and worth putting more time and money into than the Nav. Now don't get me wrong, love the Navigator. It's a really solid well built coach. This one just has less surface rust and in general seems so clean. Cabinets are absolutely beautiful walnut, never seem them so nice. All the walls are walnut too! I already like how Foretravel designed the chassis, the engine bay is so much easier to get to. For a guy who wrenches, that is a big plus.

Soooo, am I crazy??

Re: Rebuilding Crashed 1995 U295

Reply #3 – June 11, 2021, 09:45:23 am

Quote from: nbluesky – June 10, 2021, 11:20:05 pm

Honestly not sure if I am going to try to rebuild the factory step. I have to think about it.

There still is hope I could find a door as I have not called more than Visones to look for a possible used one.

At the very least, join the Foretravel Motorcade Club so you have more access to the technicians at Foretravel. Your coach is still supported by the factor in Texas, and when you're ready it wouldn't hurt to give them a call about the step.

Art

Re: Rebuilding Crashed 1995 U295

Reply #4 – June 11, 2021, 10:08:16 am

You could buy the electric step that Xtreme puts in on the step conversion cheaper than building a stock setup or talk to Xtreme and buy one of the take offs.

Re: Rebuilding Crashed 1995 U295

Reply #5 – June 11, 2021, 10:18:43 am

Life is nothing more than a series of upgrades.
If your rebuilding anyway this would be the time to upgrade into new steps and headlights. You will never be satisfied with the stock headlight reflectors and the location is just too low to work as well as if you raise them up 16 inches. At there current level they almost are at a flat projection. IMO
Scott

Re: Rebuilding Crashed 1995 U295

Reply #6 – June 11, 2021, 10:55:14 am

those all all great suggestions - plus Motorcade club will get you 10% off parts at Foretravel and Motorhomes of Texas

FORETRAVEL

Call the main foretravel number and there will be a voice prompt for the Motorcade club - you will speak to Beverly Koonce - about $125 I think, or less annually.

X-treme Paint and Graphix in Nacogdoches, TX. (Greg is best to talk to - Main number is (936) 560-5888) would be a great source to send some pictures, get a quote to fix (I know you are going to do this yourself, but it allows you to get their input) and they might have headlight parts, stair parts and door sources that will help you i the rebuild.

Re: Rebuilding Crashed 1995 U295

Reply #7 – June 11, 2021, 06:53:47 pm

So to blatantly answer your question, anyone who owns a rolling home probably should be a little crazy and deep pockets don't hurt. Personally I probably would just build a new door. Extreme door steps and since your in headlights also. Nah I don't think your crazy. Our coach was the same thing only different but COVID made ours possible. 4500 miles last week really helped reinforce our decision. Hundreds of years of knowledge right at you finger tips. So welcome as a new proud owner and everyone here loves pictures and projects, at least I do
Scott

Re: Rebuilding Crashed 1995 U295

Reply #8 – June 12, 2021, 10:34:30 am

Noah, be careful what you are pushing against with that porta-power....you may end up with a twerked suspension.

Call Rance at Extreme in Nac. He had a few doors in storage in the parts barn. You need exact measurements, as there were 3 different door sizes on that era buses.

Woody.

Re: Rebuilding Crashed 1995 U295

Reply #9 – June 12, 2021, 12:34:17 pm

My 2003 came factory new with a Kwikee step. I suggest you do the same.

Re: Rebuilding Crashed 1995 U295

Reply #10 – June 12, 2021, 12:48:35 pm

FYI
Kwikee steps are all import stuff now.....No longer Oregon, American made. They also rust up easy, especially if near the coast.
Powder coat flakes off, can get stuck in or out.
Just Sayin'
Chris

Re: Rebuilding Crashed 1995 U295

Reply #11 – June 12, 2021, 01:26:28 pm

Quote from: gracerace – June 12, 2021, 12:48:35 pm

FYI
Kwikee steps are all import stuff now.....No longer Oregon, American made. They also rust up easy, especially if near the coast.
Powder coat flakes off, can get stuck in or out.
Just Sayin'
Chris

I always thought once powdercoated it was un removable? Poor prep? I still plan to get set up to eventually to powder coat.
Scott

Re: Rebuilding Crashed 1995 U295

Reply #12 – June 12, 2021, 02:27:53 pm

Problem with powder coat is if the metal isn't properly prepared then it can lose the adhesion. Also when a crack develops in the surface and moisture can enter then it will start flaking. Nothing is better than a primer and topcoat system. Easy to repair when needed. Powder coat is very difficult to repair.

Re: Rebuilding Crashed 1995 U295

Reply #13 – June 12, 2021, 04:50:44 pm

I have powdered coated a few car frames and it is all about prep, I have had good luck with it and no major problems.
Just make sure you take it to a good shop.jmho

Re: Rebuilding Crashed 1995 U295

Reply #14 – June 12, 2021, 06:06:14 pm

Quote from: dsd – June 12, 2021, 01:26:28 pm

I always thought once powdercoated it was un removable? Poor prep? I still plan to get set up to eventually to powder coat.
Scott

To a certain extent that is true. Coastal salty air, will cause rust, at the edge, then get under the powder coating. It will come off in sheets.
I have an old gas pump I powdered coated, was sandblasted so it's prepped perfect. It does fine outdoors, but is really fading after 10 years.
I have had many other things powder coated, that have rusted and peeled. But all and all, powder coating is pretty awesome.
Chris

Re: Rebuilding Crashed 1995 U295

Reply #15 – June 12, 2021, 09:40:11 pm

Quick update: Turns out the porta power was a waste for this project. Waaay easier to just tear it all out and rebuild. I'm going to find a door. Rest will be easy.

Going to stick with factory headlight location. I really like the look of it. I want to try and keep as original as I can. I think it's a classic. Exception will be the stairs. An upgrade is in order for sure.

Here are some today progress pics.

Re: Rebuilding Crashed 1995 U295

Reply #16 – June 12, 2021, 09:43:07 pm

Quote from: nbluesky – June 12, 2021, 09:40:11 pm

Quick update: Turns out the porta power was a waste for this project. Waaay easier to just tear it all out and rebuild. I'm going to find a door. Rest will be easy.

Going to stick with factory headlight location. I really like the look of it. I want to try and keep as original as I can. I think it's a classic. Exception will be the stairs. An upgrade is in order for sure.

Here are some today progress pics.

Good job
Just put LED bulbs in the headlight fixtures, it will be like night and day (pun intended). Cheap as chips. Plenty of posts on here doing it.
I'm with you, like the original classic look too.
Looks like it needed a step rebuild anyway. Kwikee is probably the easiest as other said.
I bet there is a door out there.
Chris

Re: Rebuilding Crashed 1995 U295

Reply #17 – June 13, 2021, 10:46:56 am

If you'll be rebuilding the steps you might consider making them so they are open if possible. That would give you a longer tread for more safety. I don't like the short step treads and usually go up sideways.

Re: Rebuilding Crashed 1995 U295

Reply #18 – June 13, 2021, 07:10:31 pm

X2 on foliver. I side-hill the steps, too.

MS

Re: Rebuilding Crashed 1995 U295

Reply #19 – June 14, 2021, 10:42:06 pm

I really want to find a door that I can make work. I responded to the Door no longer made thread talking about this same door from PO when he was researching. If the 95 smaller door is truly a unicorn I want to retrofit a larger door in if possible. I know I could probably build a door, or have one made, but I want to use the coach this summer! I want to get this buttoned up as soon as possible and I know finding a used door, or even possibly buying a new one that fits the opening will speed things up.

Re: Rebuilding Crashed 1995 U295

Reply #20 – June 15, 2021, 11:18:26 pm

Quote from: nbluesky – June 14, 2021, 10:42:06 pm

I really want to find a door that I can make work. I responded to the Door no longer made thread talking about this same door from PO when he was researching. If the 95 smaller door is truly a unicorn I want to retrofit a larger door in if possible. I know I could probably build a door, or have one made, but I want to use the coach this summer! I want to get this buttoned up as soon as possible and I know finding a used door, or even possibly buying a new one that fits the opening will speed things up.

Here are the pictures of our 97 door rebuild, also installing power lock, hope it helps. Just thinking if you find a later door, would be easy to narrow it, window might be tight.
Chris

Re: Rebuilding Crashed 1995 U295

Reply #21 – June 15, 2021, 11:27:31 pm

Yeah my door is nothing like that one. It is entirely made of aluminum. It is a REALLY well made door but that in my opinion makes it quite difficult to repair. The front of the door is an aluminum skin that is rolled/pinched/welded into the body of the door which is solid aluminum as well. Hard to describe. I did not realize the other model larger doors were completely different construction...makes me think I have to find a way to get this door fixed.

Re: Rebuilding Crashed 1995 U295

Reply #22 – June 16, 2021, 07:51:30 pm

Quote from: gracerace – June 15, 2021, 11:18:26 pm

Here are the pictures of our 97 door rebuild, also installing power lock, hope it helps. Just thinking if you find a later door, would be easy to narrow it, window might be tight.
Chris

Awesome work Chris....I salute you ..!!!

Re: Rebuilding Crashed 1995 U295

Reply #23 – June 23, 2021, 08:29:52 am

I have had zero daytime hours to work on this but last night I did get the old door taken apart. I was able to cut a few welds, make a couple of decisive cuts in limited places and take it apart. It really is not that complicated of a door once it is broken down. I will keep playing around with trying to straighten things out while also hearing back from a few places about helping me out.

My big thing is I need to use the coach for the 4th at the cabin...I might be throwing a temp door in and hitting the road with it a little rough

Re: Rebuilding Crashed 1995 U295

Reply #24 – June 23, 2021, 09:54:16 pm

Made some more progress tonight. I think I am going to get this back into shape. It will need some body work to make it pretty again. The panels are getting close to straight and flat again. The outer door skin I still need to work a bit more and will need the most filler and sanding. The door frame that mounts to the opening will be next. It's pretty heavy gauge stuff, hopefully I can get it straight enough to use.

I am just taking my time using a 2# hammer, masonry hammer, some blocks of wood, various clamps, and a torch to heat some areas. It is going surprisingly well, my son is enjoying helping straighten some of the smaller misc pieces. Even my daughter came to hang for awhile tonight

If in the end I'm unhappy with it I know I could get some fresh metal bent up and build a new door. I am seeing what I can accomplish on my own first. I have a feeling it is going to work great.

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