Bulkheads

Topic: Bulkheads (Read 2321 times) previous topic - next topic

Bulkheads

October 22, 2024, 01:06:08 pm

When I got home form the last trip my left rear fender was pulled out and wheel was was back.
The bulkhead was pulled out. I have now got it aligned and the bulkhead back in place. My plan
is to completely rebuild the bulkhead but this is not the time to do it as the summer would be
better. I'm thinking if I hang three 11/2 tubes under the bulkheads and bolt them in that may make
it so I can ski this winter and fix it when the weather is right for the repair.

Re: Bulkheads

Reply #1 – October 22, 2024, 01:45:55 pm

What do you mean when you say that the wheel was back? Did the axle change position? That sounds scary.

Are you proposing to support the bulkhead so it can sit until Spring, or a makeshift repair to drive the coach?

Your idea could be reasonable or very scary.

Re: Bulkheads

Reply #2 – October 22, 2024, 04:38:42 pm

Yes the axle was to the rear. I have been talking to Scott so I'm going out and pull the wheels
so I can get get in there for a better look.

Re: Bulkheads

Reply #3 – October 22, 2024, 08:57:02 pm

Sorry I didn't take a picture of the wheel back so the first picture is the wheel back where it's suppose to
be. The second picture is the broken weld which has be broken for a long time, so the bulkhead is what
has be holding the wheels in place. The third picture is lining up the old weld. The third picture shows how
the the arms are are held by the bulkheads. The last shows the weld lined up. I will first weld the crack a
little and then remove the cold chisel and let the crack close up and continue welding. Can only weld a
little at a time and then let it cool.

Re: Bulkheads

Reply #4 – October 22, 2024, 09:32:09 pm

Sorry to be the bearer of bad news or come across negatively. You can't weld rust. There are also restrictions as to what can be done for frame welding and repairs. This is not a job for do it yourself. All of that steel needs to be cut out and replaced. Corroision at this level was the primary reason my 2004 Tropi-Cal was junked.

Re: Bulkheads

Reply #5 – October 22, 2024, 10:55:21 pm

It's not the rust that is the big problem it's the access that is the big problem. I have welded a
lot worst rust than that.

Re: Bulkheads

Reply #6 – October 23, 2024, 07:41:04 am

When I hear "bulkhead," I think of the storage bin assembly that fits between the front and rear bulkheads. That seems to be where most of us have bulkhead problems. From your description and the photos, it appears that the part of the frame that holds the axle pivot arms has come loose. I have heard the arms called trailing arms.

That is some thick steel under there, and I would imagine the rust to be WAY short of perforation.

Has anyone else had this problem? Is it a first?

Re: Bulkheads

Reply #7 – October 23, 2024, 09:29:19 am

With the right side of axle being moved that much, what do you think of the torquing forces on the left side being another problem?

Re: Bulkheads

Reply #8 – October 23, 2024, 09:49:04 am

Think one thing I would consider is sandblasting that whole area and repaint the whole thing,that's one of the worst rusted
spots I have ever seen and while your there bite the bullet and change out all the torque rod bushings,also consider adding
some buttruss plates to beef up the welded areas.

Re: Bulkheads

Reply #9 – October 23, 2024, 10:23:17 am

Matt it is the storage area bulkhead that needs to rebuilt. The trailing arms vertical support is attached to
the bulkheads which is rusted away and is welded up top to a plate which runs across the coach to the
left trailing arm support. The weld is broken and it's just service rust. The bulkhead is what has
been doing all the trailing arm support until it let go. Jerre I will be checking the left side also. I read
in the bulkhead repair search that someone had the wheels move because of the bulkheads and I don't
know if they found the broken weld. I searched because Scott told me to look. I will look at ways to beef
up the whole thing.

Re: Bulkheads

Reply #10 – October 23, 2024, 10:24:29 am

Quote from: oldguy – October 22, 2024, 10:55:21 pm

It's not the rust that is the big problem it's the access that is the big problem. I have welded a
lot worst rust than that.

Lots of good metal to work with there still. It's going to be a really unpleasant job but definitely doable. The folks that think this thing is rusty have clearly never been in the trucks I owned growing up in Minnesota. I had an 86 F150 where the only thing keeping mud from coming up through the floorboard as I was driving was a huge patch a duct tape.

I don't envy your predicament but admire your willingness to tackle this kind of job. It's outside of the wheelhouse for most.

Re: Bulkheads

Reply #11 – October 23, 2024, 10:39:46 am

Peter's coach is used in a completely different environment. I would say for most people that it would be at end of life and not repairable. This is a major problem. I know with Peters background this is within his means although it's a huge project. The bulkhead structure, more so the bottom floor is used to triangulate the lower links on the rear suspension. I fear the upper attach point vertical from the link pivot point has failed at the horizontal frame that the engine hangs off of. There is no room behind the vertical box to triangulate creating this problem. I lost sleep worrying about this last night. Once this is repaired the bulkhead and floor will also have to be addressed. Hard to imagine a bulkhead repair being smaller than other needed repaires. I've been down this road seems like too many times and have learned to avoid them. Wish we had a spare coach to swap him into.

Re: Bulkheads

Reply #12 – October 23, 2024, 10:50:05 am

Peter looking at those welds they look like they literally were cold and popped off the other structure. This is exactly what I had envisioned. Yes you lost your triangulation but they didn't properly weld leading to this failure. Those tubes are 3/8" thick and if welded correctly would have failed differently.

Re: Bulkheads

Reply #13 – October 23, 2024, 11:04:41 am

Yes Scott it wasn't welded properly. The biggest problem is getting at it to weld it properly.

Re: Bulkheads

Reply #14 – October 23, 2024, 12:54:25 pm

I'm not seeing how the bolting of the tubes under the bulkhead would solve the issue. That's if your bolting them from front bulkhead to rear bulkhead. Otherwise exactly where were these tubes be bolting to.
Isn't the problem more from the rear bulkhead attachment to the rear engine / wheel structure.

Looking at the amount of rust, I wonder if there's enough meat left in the belly iron to bolt to?

Re: Bulkheads

Reply #15 – October 23, 2024, 02:51:14 pm

Peter's 1st. picture shows a recent curb scrub possibly stressing a poorly executed weld that gave into the forces.

Re: Bulkheads

Reply #16 – October 23, 2024, 03:14:03 pm

Grind out the existing weld and go in with an 1/8inch 7018 rod and turn up the heat, nice thing about a stick weld is that you push and poke the weld pool.
IMHO

Re: Bulkheads

Reply #17 – October 23, 2024, 03:40:57 pm

Quote from: Olde English – October 23, 2024, 03:14:03 pm

Grind out the existing weld and go in with an 1/8inch 7018 rod and turn up the heat, nice thing about a stick weld is that you push and poke the weld pool.
IMHO

7018 is a great rod. 223 would also be a great rod and is a little easier to use and doesn't share the oven storage requirements. I does cost more but he wont be buying a pallet of it either. Cutting out the old weld and prep for reworking will be difficult at best. Left side is even busier with the waist storage tube. Also mentioned will be the slower pace required to keep the entire structure realistically cool. Weld, wait, weld. Letting it cool to touch. Too much other structure that wont handle the heat and could cook off. Not a fun project at all. Very interesting from the back seat though.

Re: Bulkheads

Reply #18 – October 23, 2024, 04:59:09 pm

The rectangular tubes would run front to back and I would weld 3/8 x 2 flat iron on the end
of the tubes and bolt them into the 3/8 thick angle iron by drilling and tapping the wholes.
This is only a temporary repair. I would do a proper job next summer and rebuild the bulkhead.

Re: Bulkheads

Reply #19 – October 23, 2024, 05:39:16 pm

7018 rod needing an oven is nonsense, as soon as you strike an arc the rod dries out immediately, in the 40 years that I welded I never used an oven. They're low hydrogen, never understood what that meant however I've used 7018 for years off the back of my welding truck with my old reliable Lincoln SA 200 pipeline special.

Re: Bulkheads

Reply #20 – October 23, 2024, 05:45:56 pm

I just got off the phone with foretravel and they do not have a drawing for the bulkheads. Does anyone
have a bulkhead drawing for 99 36 foretravel.

Re: Bulkheads

Reply #21 – October 23, 2024, 05:47:25 pm

You talked with James Triana???

Re: Bulkheads

Reply #22 – October 23, 2024, 05:51:10 pm

No I talked to Brad and he said they lost them in a fire and he said when they have to repair one
the use the old one as a copy.

Re: Bulkheads

Reply #23 – October 23, 2024, 05:52:32 pm

Quote from: oldguy – October 23, 2024, 05:51:10 pm

No I talked to Brad and he said they lost them in a fire and he said when they have to repair one
the use the old one as a copy.

I'm pretty sure that fire was before your 1999 was built. It's the old coaches that they lost the documentation on.

They should have yours. Try to get ahold of Triana.

Re: Bulkheads

Reply #24 – October 23, 2024, 09:37:23 pm

It's been almost 20 years since I stopped welding so a lot of information has slipped away. I don't know if you can get a grinder up in there safely and then I remembered " gouging rod " for use with a stick welder. You have to turn up the amps a bit offhand I can't remember how much but it's good stuff in tight places. Instead of dragging with a conventional rod you push into the weld and let it drip. Well it's a thought.

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