Before Chassis
Here is the beginning, this is everything that went on before we mounted the body to the chassis. In the beginning---- there was the beast and the beauty, they both had their own lives and their own mission. Here is how we got them ready for the wedding. Enjoy
SO--- all that said, here we go. Here
is the coach we will do the mod with--
This is a 1976 GM floorplan 26 foot coach in overall good condition. It was purchased from the previous owner who did take good care of the coach. There is a slight rod knock in the motor so it's a good thing we're changing the drive train or we would need to rebuild the motor. The coach drove well down from Niagra Falls so it will be a great core coach for this project.
First things first, while we are waiting to
procure the drive train, we will go through the systems that will remain with
the rear frame section namely the rear suspension. so the rear wheels come
off
for a looksee at the rear wheel bearings and brakes
.
The coach will also be fitted with our all new 4 air bag system (quadrabag) rear
suspension kit so we will be outfitting the rear suspension completely before the coach
hits the ground again.
There are many behind the scenes work to be done on this completed project. Sure the chassis of this coach will be most unique but the rest of the coach needs to equally be exciting. The exterior finish will be right out of Picasso's drawing book and the interior appointments will be-- well lets just say appropriate.
I've worked up a block flow diagram for the Audio/Video system I'm proposing to install. At this point the only 2 components set on will be the KVH satellite receiver and the Pioneer AVIC-N3 or whatever will be the "latest greatest" offering. There is such a selection of components for this application but remembering this system is not only to be an awesom audio/visual thing but it's also an integral part of a live in motorhome so having GPS, backup camera, XM for the road and other features is a must in my eyes for the total use.
We will have servo controlled mad and sub bass cabinets that will tuck away in stealth mode while the coach is to be a "motorhome"-- I mean you don't want to feel you are living in a speaker box -- them come out for a visual display when everyone wants to play. These are basic concepts for the total system so we take these ideas and from here turn them into reality. In my previous life BGMC (before GMC), I was pretty heavily involved in the consumer electronics industry working for Panasonic, Technics, Teac and others. I am excited to have the opportunity to dig back into those wild days of big sound and come up with a suitable sound reinforcement system for this coach. We're going to have fun with this. "Unique Whips" move over, let me show you how a real dropping system is put together! We're talking band pass boxes here, amp display, power caps, the works. Now we're not talking about spending the big bucks those high end salons require for their services like this-- hang with me on this and let me show you how it's done-- just can't wait for this part of the build! Stay tuned and bring your ear plugs.
We are now preparing for our discovery on the
modifications that will put together our classic body to this all new chassis.
To that end, we will be using another coach body and chassis to document the
modifications needed. This will be our pattern and "lab rat" if you will.
This is not just a one time build, we also want to take every care to make this
coach the best it can be. Yesterday, we used the flat bed as a tow vehicle
(see everyone needs a purpose in life!)
and brought over to our area the "pattern coach"
for breakdown. Lou helped
and the evening found the interior stripped to the door
.
Lou actually replaced his frame rails himself so he's going to be a great pair
of hands on this project-- thanks Lou for your help and support.
This coach will be taken apart and modified as needed to document this process.
The actual coach is being delivered to paint this week to start in on that
metamorphosis, things are getting ready to start happening, stay tuned.
The floor of the pattern coach was no match
for Lou and his destructive techniques. The front deck came apart with
little resistance
,
then the main floor fell first pulling out the wood, then the composite foam
sheet
and the the aluminum
we're down now to the root mean
The sound equipment arrived special delivery
by my rep Rick David. Rick worked with me back in 86 when I was part owner
in an auto sound business and had stayed in the industry since
So what's this thing in the hat box? Oh man, it's our 12" professional
sound MA audio sub woofers
.
Raymond told me to make the sound system "sick" and you guys know I'm just the
guy to do that! We're got @ $5000 at cost of sound reinforcement gear for
Raymonds Duramax Monster and next comes the designing of the band pass
enclosures and placement design. Man, this is one of the real fun parts of
this project. Oh sure the chassis will be awesome so the sound system has
a high bar as well.
Back to the project coach body, Kevin is busy
stripping the painted over original decal striping from the body
The tough one here was the decals had been painted over. Normally we would
use just an eraser wheel to pull off the decal but with the paint on top, Kevin
is using first a heat gun to losten the adhesive then he will use DX-440 to
chemically remove the glue residue. DO NOT EVER DA the decals off, not
only does it not work but you will creat many hours of block sanding to get back
to a smooth surface. Trust me on this one!
We're working on several fronts at the same
time on this project. Not taking anything to risk, we are building up a
new rear suspension bogy set for the new chassis. Jesse is currently
disassembling a pair of bogys
,
sandblasting each part, prepping and refinishing each. Today, our new pin
and bushing set arrived
which will totally renew all wearing parts. All components refinished and
ready,
we will start that build up today. It's not the expense but the quality of
the finished product we have our eye on.
Good news, we have the folks at MA Audio throwing in with us on the Audio/Video system design. I'll give you more details on that as it progresses.
The actual coach is now getting attention,
you must break eggs to make an omelet-- and a nice looking motorhome as well.
The coach is inside now and the body is coming apart
Kevin is still burning off the original painted over decal striping
with a paint scraper and a heat gun. All the way around the coach, the
decal is giving Kevin *&$%!
.
Steve and Greg are pulling off ladders, vents, rails and the rest of what makes
up the exterior of the coach. We're getting ready for a trip to Walters
and the new wild paint job.
We're a little behind schedule but maybe can catch up on the stripping process,
wish us luck.
It's confirmed, we have a second Duramax project slated. And speaking of wild, this one will be on a 23' body! Oh Baby, can you say "rocket"? Boy, if this isn't getting exciting now, on a 26' coach the best analogy I can think of is a drilled out Pinto with a 351 Cleveland stuffed in-- and then here comes a 23' coach-- Holy Moly, get back up on the porch, the road and even the sidewalks will not be safe!
Sanding, sanding and more sanding, it's what
makes a quality paint job quality but it sure makes you wait
Kevin has the decals and glue off now and he's started in on filling holes.
You say what holes? Man, the previous owners must have loves self tapping
screws! The more he digs, the more we find
holes under stuff that was screwed on, holes, for logos, snaps,
holes for panels, plaques and well holes for holes sake I guess
and every one will be filled, sanded and feathered-- hey, it's gotta happen.
The roof is finally cleared off
ladder gone, rails off so this puppy is about ready to hit Walters hands. The
finish on this coach is critical so watch how we fuss over it.
More body prep is where we are right now.
The chassis is somewhere on the road but we need to spend the time to make the
exterior prep to where we want it. We welded in the original stove vent
then Kevin filled it in and blocked it down
Windows are now out and the fifty million holes are filled
man, was there any part of the body that Kevin liked!!
and thats not dandruff , thats sanding dust! We'll be ready for paint on
Monday. These steps are always involved in a quality paint finish.
Hang with us, we have more work coming.
Jesse started in on the back frame mods
yesterday
This frame is too long and too wide for our GMC body so something has to give.
Members go to CMW Member service
and scroll down to "member mechanical" for more
All of you that are following our progress on this GMC/ Duramax project I feel are a part of a very exciting chapter in the evolution of our classic coach. No, this is not a simple build and no it will not be inexpensive but anything worth doing is worth doing right and to the best of it's ability, all the components of this job are in motion, one of which has been a subject of great debate-- namely the separating of the original chassis from the body and it's fitting to the new Duramax chassis. Many have called asking how we would do this and that-- well, the answer to those folks is about ready to come. With the chassis with it's basic modifications complete and the body broken down to it's "root mean", we are now ready to fit the 2 together. Question is, How to do it"? I have seen straps used through the windows with an overhead crane-- that worked but that takes some pretty specialized equipment. Who knows, maybe down the road we can assemble such a rig but for now-- we must use whats available to us.
Our lift will be the lever that brings the
coach apart then back together. Our "pattern coach" is ready on the lift.
It has been prepped for this by stripping out the under side of the frame--
tanks, hoses, lines, cables, motor, tranny all have gone away leaving the bare
frame with it's body on top
.
The mounting supports have all been removed so with the body loose from the
frame, all thats left is to separate the 2. We have scaffold secured the
body with the hopes of dropping the lift and the original frame
This is a temporary support
which will allow the frame to separate from the body far enough to construct
crossbeams on a "post/ beam " structure to hold the body in the air while
allowing the frame to drop out from the bottom. Lou, with his frame
experience gained from replacing the frame rails in his own coach, now come into
play on this tedious part of the project. Bring her down00 carefully,
watch the scaffold-- slowly, a bit more-- there it si, it's coming, coming-- I
can see light
We've done it!! The body is free from the frame!
.
Now Jesse is on duty welding up our main support structure to allow the frame to
finish it's travel to the ground. With the old frame out, our new Duramax
frame will be fitted uned the body then brought up into place as final
modifications are made. The old frame is coming out now and the new frame
will be fitted to our pattern coach body, modifications documented for the real
fitting to the actual body. Things are getting fun now!!
As you will remember, we are documenting the
mounting process using our "pattern coach" to line up all the mods needed.
The coach has been on the lift loosing all of it's acc.- you know tanks and
lines, hoses, brackets and all of that stuff. Then a couple of days
ago we hit pay dirt and the original frame and body were ready to part company.
Lou was an awesome help to Jesse to get us to this point. So disconnected
and hovering seemingly weightless, the body was ready to loose it's spine in
favor of it's new one.
and then there is went, members go to for
more.
You know what it means when you see that big,
beautiful 19.5" tire filling up and more the front wheel well of the pattern
coach
---
it means "Elvis has entered the building", "The Eagle has landed", "The lime is
in the coconut" and "The beef is in the bun"---- the Duramax chassis has a GMC
on it, but you already saw that. Members go to
Member Mechanical for more. Next we
will document the new body mounts and supports.
This fitting process using our "pattern"
coach has yielded results so now we are ready to pull the Duramax chassis back
out
and with Jesse's help
do the mods found and prep the chassis for it's real body. The pattern
body gets it's original frame back
and the pair go to the sidelines their job done. Children, don't try this
stunt at home!
