American Coach: Basement Rust Repair

[Meames1]

The floor assembly is done ! Installing the panels was a nightmare, but done. You basically get one shot with the adhesive and it sticks Now. lol. I tried doing it myself and had to get my son to help. I'm going to use a 2-part epoxy seam sealer that the panel manufacturer uses to weld the panels, but going to wait until the floor is installed so everything is in position. Overall, I'm very happy with the new floor and convinced it will last much longer than the original. Now, on to the uprights.

[Meames1]

For those following along, you'll remember I originally thought I could repair the uprights by welding in new bottom horizontal tubing and maybe patching a piece of vertical tube here and there.

As I went along I figured it would be better to remove all the systems and the uprights to be able to rebuild them in the shop instead of outside during the winter.
Boy, am I glad I did. Starting the uprights it's now very clear that they are going to basically need complete rebuilding...there is nothing left !!
Had we just loaded the basement up when we bought this rig and by the time the tanks were full, there is no doubt the entire basement would be sitting on the ground somewhere.

Anyways, it will be right and I can be confident in the repair once done.

[Steverino]

Hoo boy that's ugly. Good that your OCD kicked in and you're taking it all the way. I appreciate someone with attention to detail and taking the long view. Watching with interest...

[Meames1]

One upright built yesterday and painted, just have to install the insulation and outer FRP panels once the paint cures. Started building the second panel and found yet another tubing size, currently I have 1 1/2" square, and 3/4" x 1 1/2" for the two main areas of repair. Now I've found, what I will call the "intermediate" uprights (run parallel to the coach) are made out of 1" x 1 1/2" tubing. So this will necessitate another steel order, but I was probably going to run out of 1 1/2" square anyway due to the additional uprights.

If I may jump on my soapbox for a minute...
I usually don't complain much, especially when it comes to questioning a companies engineering since what the heck do I know. But, I cannot for the life of me understand why AC did not paint the steel frame work with some kind of rust inhibitor. Another thing I'm finding is the frame tubing only being welded on 1 side. Out of four sides of tubing, only 1 side welded! Obviously, this was sufficient as strength was not the issue, rust was...and it IS 20 years old. So, maybe there was a concern of the adhesive not adhering to paint and that's why it's omitted, but come on this was almost a 1/4 million dollar coach back in 99 !

Anyway, on to the pics.








You'll notice I reused the upper tube, and I hope to on all the uprights. The upper tube has the bolt holes already in place to attach to the coach and this will make reassembly much easier by going back into the same holes.

[Meames1]

One upright complete !


The original had this wood frame for a vent due to this compartment holding the propane tank. AC just glued this in place when they vacuum bonded the panel. I wanted it more secure, so I drilled and screwed it to the frame. Once the panel adhesive dries, I'll cut out the opening. The strut support bracket was reattached with SS screws.









Sprayed both panels and let tack.





Then I started building the opposite side panel and found it's built different with an additional brace for some reason ? Maybe an option or something mine doesn't have, I don't know. Well, I'll install it like the original....but of course with a miter cut and not like they did it.






Painted with POR 15 and ready to assemble tomorrow.

[wildmanbaker]

Who knows if the frame work was to have some protectant on it or not. Production, protection, protection, is the name of the game. They may not had time for the coating to dry for assembly, or they just skipped that step. Not capping the ends of the tubes didn't help anything either. You seem to know what you are doing, keep up the good work. I have a question, did you have help with the bottom frame work turning it, as I know it is not only heavy, but awkward also.

[Meames1]

Originally Posted by wildmanbaker

Who knows if the frame work was to have some protectant on it or not. Production, protection, protection, is the name of the game. They may not had time for the coating to dry for assembly, or they just skipped that step. Not capping the ends of the tubes didn't help anything either. You seem to know what you are doing, keep up the good work. I have a question, did you have help with the bottom frame work turning it, as I know it is not only heavy, but awkward also.

Yes, when I move the basement frame I have my son, daughter, and wife all out helping. Of course my strongest son (174lb College Wrestler, all muscle) is away to school. But we get by. Thanks.

[Meames1]

Originally Posted by Meames1

Then I started building the opposite side panel and found it's built different with an additional brace for some reason ? Maybe an option or something mine doesn't have, I don't know. Well, I'll install it like the original....but of course with a miter cut and not like they did it.

Attachment 268491

Sidebar : I found out what this extra vertical brace was / is for. While looking at other threads comparing the Eagle's panto graph bay doors, the hinge assembly is quite large and elaborate on those style doors and they bolt on to that support. The reason the left side panel I did first did not have it is because that side is under the slide and even the Eagle uses the standard style door in that location (still doesn't explain why they couldn't bother to cut the miter at the top of the brace) .I know, totally useless information but it bugged me not knowing why it's there...now I know!

[SlowJoe]

Looking good! Hard to believe they would leave all of the steel bare. That's just shameful!

[Meames1]

I'm not planning on posting every single frame I rebuild, I'm sure nobody needs to see the same thing over and over. But, I wanted to show the first "large" 8' wide frame I tackled. This is the second frame back from the front...away from direct contact with road salt, water, grit etc. It's the first one I have found that still had a significant amount of good tubing left. I only replaced the bottom tube, both outer uprights and one inboard upright. The rest of the steel was in good shape and I found no reason to completely rebuild it. Saved me about 12' or so of tubing.

[mchero]

I owned a 93 Pace Arrow Diesel for 12 years. It was assembled on the American Coach assembly line. I was very surprised galvanized screws where used under the rubber belting down the sides of the coach. Over a few years they start to rust. The basement assembly is similar to what your working on. No rust prevention what so ever!

One needs to get on their back and do a close inspection of the underside of their rigs. A real eye opener on these older rigs.

[Meames1]

I now have all the 10 uprights rebuilt, structurally anyway. I put the last coat of POR15 on the final 3 yesterday. I just have those 3 to install the insulation and FRP panels. The one 8' panel has a bunch of water lines through it and holes for the heat tubing etc, so that will take a little longer finishing up. But, excited to have this phase basically complete. I was all ready to go full steam ahead and start re-installing the panels and ultimately the basement floor when I sat back and started thinking a little. Right now the whole undercarriage of the coach is exposed and wide open. Now would be the time to do any little projects I wanted to do on the chassis. A little cleaning and painting here and there, I bought new air bags just because I don't know how old they are, cleaning slack adjusters and brake chambers, things of the like. So, I'm going to try and tackle some of those items while it's apart and easy access. One thing I must deal with, as some may have seen in another thread I started a while back, the PO must have had a power steering hydraulic hose failure and instead of fishing a new hose through the frame they ran it under the coach basement floor on the roadside. So, I need to resolve that and run it where it belongs before I put anything back together. I'm attaching some random construction pics of the last uprights.

[Meames1]

Anyone know where I can get these grey plastic trim pieces ?



I have looked all over the place, on both RV parts and plumbing supply sites to no avail. They are grey plastic with a 1/2" hole to trim around pex tubing and they're at least 20 of them in the basement alone. I did find these https://www.amazon.com/dp/B07TMY82T1...v_ov_lig_dp_it
but they are domed and not flat, so if I were to put screws in them I'm afraid they would distort and look crappy. AC installed these with sealant and screws where the tubing passes through the basement floor to the exterior (all the drain tubes).

I tried REV, no luck. I may have to make them...

[spinroch]

Amazing work! I am impressed!