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Topic: Rebuilding Crashed 1995 U295 (Read 9064 times) previous topic - next topic

Re: Rebuilding Crashed 1995 U295

Reply #20 –
Quote from: nbluesky –
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 –
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 –
Quote from: gracerace –
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 –
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 –
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.

Re: Rebuilding Crashed 1995 U295

Reply #25 –
Your kids are wanting you to have it fixed so they can go out camping.

Based on the before and after pictures of that door, it is looking great. 

Re: Rebuilding Crashed 1995 U295

Reply #26 –
Noah.
 I'm sure you have the door weather strip figured out.  I know when we ask FOT they no longer have it.  Curious what your w.s. Plans are ?

Re: Rebuilding Crashed 1995 U295

Reply #27 –
If FOT doesn't have the door weatherstrip then call Xtreme Graphics. 

Re: Rebuilding Crashed 1995 U295

Reply #28 –
My door has an internal seal/gasket and it was intact. I removed it and  I just have to glue it back on when I'm done!

Re: Rebuilding Crashed 1995 U295

Reply #29 –
More progress tonight.  Couple of pics.

Re: Rebuilding Crashed 1995 U295

Reply #30 –
Making fantastic progress on the door 30 mins to 1 hr at a time! I have some real hours reserved this weekend to get as much done as I can. The door frame is all straightened out and fits like a glove back in the opening. Next is to reassemble (dry fit looks great) the front and door, epoxy and rivet everything back together, and rebuild the stair box. I hope to have a door in by the end of the weekend. I'll get some better pics soon.

Re: Rebuilding Crashed 1995 U295

Reply #31 –
Quote from: nbluesky –
Making fantastic progress on the door 30 mins to 1 hr at a time! I have some real hours reserved this weekend to get as much done as I can. The door frame is all straightened out and fits like a glove back in the opening. Next is to reassemble (dry fit looks great) the front and door, epoxy and rivet everything back together, and rebuild the stair box. I hope to have a door in by the end of the weekend. I'll get some better pics soon.
Looking good. I had a old A and P instructor that showed you could anneal to soften aluminum by covering with a pure acetylene flame suet then add oxygen and burn the suet off and let it cool. Reduced the work hardening. Bring that frame by the house and I'll tig it up for you. I've also got 3m scotch weld adhesive I can give you too. With the scotch weld it will bond to styrofoam and not melt it. Bond the entire thing together.
Again looking much better than what you started with.
Scott

Re: Rebuilding Crashed 1995 U295

Reply #32 –
Yesterday was a huge  15 hr day. Finished bending parts for the door. Reassemble all the locks and handles. Put the inner and outer door skins back together, lots of rivets and epoxy curing overnight. I tried my luck at brazing aluminum, never done that. It worked okay. Luckily it is in an area completely covered because it doesn't look great. I am hesitant to share but this is real life learning lessons for me. Be nice :)

Tore out old stairs. Built new ones with an extra inch of tread depth. Put two coats of foundation waterproofing on the pywood box (no pics yet) as the original factory idea of wrapping in aluminum was bad. It just held water. Totally rotted out. For how clean this coach is I'd bet more people have rotted stair bottoms than know it.

I hang the door today, it's a big moment for me! Wish me.luck :)

Re: Rebuilding Crashed 1995 U295

Reply #33 –
Quote from: nbluesky –
I tried my luck at brazing aluminum, never done that. It worked okay.

I hang the door today, it's a big moment for me! Wish me.luck :)

You're brazing looks good because it wet the underlying metal.  Congratulations.

We make our own luck.

And yes, re-hanging the door is a big moment.  A time worthy of celebration and ceremony.  Recognition.
Consider anything other than "Isn't it supposed to do that?" High praise indeed.

Re: Rebuilding Crashed 1995 U295

Reply #34 –
 ^.^d I love the can do attitude ^.^d

Re: Rebuilding Crashed 1995 U295

Reply #35 –
Quote from: nbluesky –
I tried my luck at brazing aluminum, never done that. It worked okay. Luckily it is in an area completely covered because it doesn't look great. I am hesitant to share but this is real life learning lessons for me. Be nice :)
So IMO since you have never used this product, don't do this for a career, (yet) you have accomplished a good repair for which most others can only admire or complain about. Is it going to fail? Probably not, but you did represent a lifetime warranty to the original purchaser of your skill, more than I would do, it's a home run. I personally think you are accomplishing what few can do. And you didn't spent 10k to do it.
CAN'T NEVER DID NOTHING!
Very well done.
Scott

Re: Rebuilding Crashed 1995 U295

Reply #36 –
One does NOT learn by NOT trying. Go for it!!

Re: Rebuilding Crashed 1995 U295

Reply #37 –
I have never brazed aluminum but what you did looks good. We have a local boat repair guy that does our aluminum welding. You have me wanting to try it. On your door, what you have done will work and is exceptional. Wait till July 4 to hang it......go buy more fireworks to celebrate.

Re: Rebuilding Crashed 1995 U295

Reply #38 –
Cobalt blue welding lens help to see the difference in the solidified and molten aluminum. Brazing rod has a lower melting alloy and is softer than base metal but the difference between the solid, to liquid is real close together. And you're using a acetylene torch . 😁 It's good fun. Tig controls the temperature  range closer and isolates the heat tighter. And a perfect controlled atmosphere. That crazy mig machine just does magic crazy stuff on thicker aluminum and makes my welds look like I know what I'm doing, and I don't. Again good fun
Scott

Re: Rebuilding Crashed 1995 U295

Reply #39 –
Noah, probably too late but some coaches have a hinged compartment for the middle step. Kinda nice to have.
 Great work!