Community Forums

Emac · 05-18-2018, 08:08 AM

I know this has been brought up before but I couldn't find any definite answers on the subject. Does anyone have any knowledge, info, or pictures of what was used and how the halo kits were installed either by Monaco or a third party vendor? I know all the cabinets, T.V. etc. must come down to get to the steel structure above but after its opened up how did they brace the front cap to stop the flex and movement?

Thank you all in advance.

CountryB · 05-18-2018, 09:39 AM

What is a Halo kit?
I've heard this term referring to the day-time-running LED light kits people install around their headlights (on cars).

8.3Oilbuner · 05-18-2018, 10:25 AM

Good morning Emac & CountryB; Yes, I have read and heard a lot over the years of the Halo Kit. Monaco on certain models, mostly some around the mid 2005 years, did not put enough support in the top of the front cap, behind the upper front cabinets, to keep the windshield in place in the big rubber gasket in the cap. This also started when Monaco went to their Pan-A-View, one piece windshields. Some owners would have a corner of the windshield pop out going out of a drive way. Some would level the coach and have a corner of the windshield pop out. Monaco compiled a kit, as so to speak, to provide support for the front cap so the windshield would stay in place. Yes the front cabinets were removed to install the reinforcing. I am sure in time some owners who had this done to their coach will respond.

vito.a · 05-18-2018, 10:30 AM

Call Source Engineering. They are great guys that worked at the old Monaco through the years.
(541) 343-0293

BigSkyBob · 05-18-2018, 10:44 AM

I had the halo kit installed in my coach a year after purchase because the windshield cracked in the upper right corner. This was a known design flaw and Monaco stood behind the fix. This only happened on coaches up to and including the 2008 models as Monaco redesigned the front cap to reduce the curvature of the windshield on the edges in later years. There is a distinct difference in the 2008 and 2009 and later windshields. I watched most of the process at the factory service center when I returned to the factory to have the items on my punch list taken care of. They did not removed any cabinets but they did take down the front portion of the ceiling to install the halo kit. There was some MIG welding of additional braces to reinforce the structure of the front cap and I will say the factory techs did an awesome job on my coach. I might add they had a fixture to hold the new windshield in place to check the clearances between the glass and the fiberglass and I was shown where the fiberglass was in contact with the glass. They ground away some areas that were too close to the glass and if I recall from 10 years ago that gap had to be in the neighborhood of 1/2". I have crossed speed bumps and other things that put a pretty good twist in the coach but the windshield has never leaked or cracked since.

CountryB · 05-18-2018, 11:55 AM

Quote:

Originally Posted by BigSkyBob

I had the halo kit installed in my coach a year after purchase because the windshield cracked in the upper right corner. This was a known design flaw and Monaco stood behind the fix. This only happened on coaches up to and including the 2008 models as Monaco redesigned the front cap to reduce the curvature of the windshield on the edges in later years. .

This is very interesting and concerning --

I have a 2005 Beaver (Monaco) with a cracked windshield now (upper left corner in my case). I'm still in process of getting it repaired, but now I'm wondering if I need to do some other repairs/modifications before the new glass is installed.

If there is anything that "should" be done (and can be done by owner) this is my chance.

I'll be subscribing to this thread.

Emac · 05-18-2018, 12:50 PM

Quote:

Originally Posted by BigSkyBob

I had the halo kit installed in my coach a year after purchase because the windshield cracked in the upper right corner. This was a known design flaw and Monaco stood behind the fix. This only happened on coaches up to and including the 2008 models as Monaco redesigned the front cap to reduce the curvature of the windshield on the edges in later years. There is a distinct difference in the 2008 and 2009 and later windshields. I watched most of the process at the factory service center when I returned to the factory to have the items on my punch list taken care of. They did not removed any cabinets but they did take down the front portion of the ceiling to install the halo kit. There was some MIG welding of additional braces to reinforce the structure of the front cap and I will say the factory techs did an awesome job on my coach. I might add they had a fixture to hold the new windshield in place to check the clearances between the glass and the fiberglass and I was shown where the fiberglass was in contact with the glass. They ground away some areas that were too close to the glass and if I recall from 10 years ago that gap had to be in the neighborhood of 1/2". I have crossed speed bumps and other things that put a pretty good twist in the coach but the windshield has never leaked or cracked since.

BigSkyBob, Do you happen to know or remember what type of bracing they installed, how it was installed, and where it was placed?
Thank you for the info

BigSkyBob · 05-18-2018, 02:44 PM

Emac, I don't recall very much regarding the mod to the front cap I'm sorry. This was done over 10 years ago and I have issues remembering what happened yesterday. I recall they had an aluminum ring that was in two pieces that was attached to the existing front cap structure and some shorter vertical aluminum braces that were MIG welded to that ring and to the side structure. It took them them the better part of two days with two techs working on it to complete. It must have done the job as my windshield has never leaked or cracked since the mod was done. Sorry I can't be of more help. I don't know if Source Engineering ever got involved in that but it's worth a call to inquire. Also I understand some of the original Monaco techs are still working in the Junction City, OR shop so that might be a source of info.

8.3Oilbuner · 05-19-2018, 10:55 AM

Good morning, or afternoon CountryB; I know it is quite a distance from where you are located, but you might want to give RV Glass Solutions in Coburg,Or. a call. They address all types of windshield problems. Had my drivers side window replaced in 2015. Great work done by their techs. While in there getting the work done were many other coaches, Monaco, that had cracked windshield problems. Had a 2005 H.R. Imperial behind us that just went through an evaluation to fix the windshield cracking problem. I listened in, with the owners permission, on what it was going to take to fix the problem. In his cap in some areas the mounting area for the windshield need to have material removed and in other areas material needed to be added. Was quite an extensive conversation to listen to. RV Glass Solutions have others across the U.S. that they go through to solve the windshield problem. I know you are in Fl. near Orlando. I thought one time I read, not sure, that Alliance Coach near Lakeland Fl. had someone who handled cracked windshield problems. Hope this gives you a better direction to go on getting your windshield problem fixed. Kind of glad I have the old 2 piece windshield. Have a great day!

CountryB · 05-19-2018, 11:06 AM

Thanks for the info on the Halo fix.

My windshield cracked because my leveling system failed and the frame twisted enough to crack windshield. I'm having the glass replaced as soon as i finish the HWH repairs.

I don't think I will focus on the Halo fix - and just replace the glass this time. If the glass ever cracks again, I'll get with Alliance Coach and at least I will know enough about the Halo fix to discuss somewhat intelligently with them.

Ivylog · 05-20-2018, 08:56 AM

I believe the halo kit was ONLY needed on rigs that have windshields with small radius corners... starting in 2005. Cracking from not enough clearance around the windshield is a different issue and easy to measure and easier to fix.

Red Rocker · 05-20-2018, 09:33 PM

Mine is cracked, lower drivers side 05 Camelot. Messaged another owner that's having his fixed to the tune of 10K, I'll just have to live with the crack.

Pusherpilot · 05-21-2018, 10:14 AM

Our 04 Imperial has cracked 5 windshields since new. Mileage now is 120k appx. The last one, last year, was replaced under the Comprehensive policy but the insurance co has stated they would replace it now but would not replace it again until we have the coach "inspected" and any required repairs done. The ins co stated the inspection and repairs were to be done by a "qualified" shop but did not describe or give us the name of a shop they would accept. The replacement was done and the installing crew stated on the bill that no defects were seen. We wanted to have the work done in Phoenix last winter but the shops there wouldn't go for the ins co terms. After hanging around Quartzsite for over a week we simply went back to Mo.

Back when we first cracked a windshield we took it in on warranty and they replaced it but would not discuss the "halo kit" or any other any other repair solution to permanently fix the problem. We went to Coburg, Or. three time and Elkhart, In. twice with warranty repairs. Later we were told that the halo kit was only being used on some models (not ours) but had been told by other owners of our year coach that they had had it done under warranty. I know Monaco was in the act of trying to go bankrupt etc during this time, and the stonewalling and arrogant aggressive attitude of the management of the warranty and repair shops was intense.

Pogo397 · 05-23-2018, 07:02 PM

I just went through this with my 2007 Camelot 42PDQ. Broke 2 windshields in one year. Took it to rev group in Decatur, IN to have it repaired. They said the windshield hole was not big enough and the glass was hitting the fiberglass. 5 months and all is good. Make sure they seal both the windshield and rubber gasket to the cap.