Rebuilding '94 Holiday Rambler Navigator

[nbluesky]

Pic of the glue behind the panels.

[cwk]

Originally Posted by nbluesky

Pic of the glue behind the panels.

Thanks very much for sharing. It is not only interesting, but very helpful.

I am doing something similar (adding 1/2" blue foam plus 1/8" plywood and wallpaper) to the existing walls during our current remodeling. Yes, I am removing the existing wallpaper to avoid an extra vapor barrier in the middle of the new wall assembly.

In addition to increasing the R-value of the walls (and ceiling) I want to create a thermal break where the steel framework is conducting the heat from the hot sun into the interior.

Would you mind sharing the name of the polyurethane foam glue you are using?

Thanks!

[nbluesky]

Thanks for the feedback! I am glad it is helpful and just subbed to your rebuild thread! I have some reading to do as it's 25 pages It's good to know I am not the only crazy one putting so much time and effort into an old classic.

I was very surprised to find the construction of my Navigator included thermal break layer of insulation on the walls and the ceiling. It is SO MUCH more insulated than my older class C. It's not even close. While I was at it and had extra 1/2" foam material I went ahead and added an extra layer in the tops of the cabinets. Figured it wont hurt and didn't want to waste extra foam

I am using Great Stuff Foam and I buy it at Menards. It's about $12 a can and you need to have a foam applicator gun. I use the gun all the time for applying expanding foam insulation. If you have to buy the gun it costs about $40.

[nbluesky]

Hello again, back with some fresh updates on the beast! I wanted to look at the oil in my front hubs and all I did was touch the one side and it broke open. I searched the site and found out this is a common part to replace. I order a new hub window and got it about 2 weeks ago, it was the wrong size! Apparently there is a smaller one and a bigger one that look identical, oops. Ordered the correct one and it was so nice out I thought I should take a break from the inside for a little exterior job.

Super easy job, took all of 30 mins including getting all the tools out to re-filling and cleaned up. The oil that was in there was filthy black and nasty looking. I am guessing that has not been changed in a long time.

[nbluesky]

Some other updates:

-Got the HWH leveling motor back from the shop. Apparently the motor got so hot it un-soldered itself at the brush to terminal connections. They fixed the solder and new brushes and everything else looked good. $94 and ready to go back into service.

- I need one hydraulic solenoid for the system. I did a resistance test on all of them at the bench and one was shorted out. That perhaps is what caused the motor to fry. That and me running way to long not realizing it was getting hot! HWH said 4-6 weeks out on solenoids but I found an RV shop in Florida that had one (Independence RV) and they shipped one out for $320. A bit more than HWH but in stock.

-I needed new seals for the rest of the solenoids as I removed them all and wanted to have new orings. HWH sells a kit good for 4 solenoids for $10 but they charged me $17 to ship a tiny little box that weighed less than 1#. Was a little disappointed about that. I asked them what shipping costs would be and they said it is whatever their rate is. I find it really hard to believe their rate is $17 to ship an itty bitty light box 2 states with ground service...

- I just received my new 600# torque wrench and 12 ton "US Jack" bottle jack. Next exterior adventure will be to pull all the wheels and start looking at brakes etc.

-Interior is coming along nicely. I will have updated pics soon. The new RecPro sofa arrived today. Carpet is installed. Things are getting close to buttoned up in there. Then we just have to spend a day deep cleaning the entire interior.

[kees boode]

Originally Posted by nbluesky

Some other updates:

-Got the HWH leveling motor back from the shop. Apparently the motor got so hot it un-soldered itself at the brush to terminal connections. They fixed the solder and new brushes and everything else looked good. $94 and ready to go back into service.

- I need one hydraulic solenoid for the system. I did a resistance test on all of them at the bench and one was shorted out. That perhaps is what caused the motor to fry. That and me running way to long not realizing it was getting hot! HWH said 4-6 weeks out on solenoids but I found an RV shop in Florida that had one (Independence RV) and they shipped one out for $320. A bit more than HWH but in stock.

-I needed new seals for the rest of the solenoids as I removed them all and wanted to have new orings. HWH sells a kit good for 4 solenoids for $10 but they charged me $17 to ship a tiny little box that weighed less than 1#. Was a little disappointed about that. I asked them what shipping costs would be and they said it is whatever their rate is. I find it really hard to believe their rate is $17 to ship an itty bitty light box 2 states with ground service...

- I just received my new 600# torque wrench and 12 ton "US Jack" bottle jack. Next exterior adventure will be to pull all the wheels and start looking at brakes etc.

-Interior is coming along nicely. I will have updated pics soon. The new RecPro sofa arrived today. Carpet is installed. Things are getting close to buttoned up in there. Then we just have to spend a day deep cleaning the entire interior.

[nbluesky]

Well today was a great day! Installed the new RecPro sofa bed. It was super easy to install and seems to be of decent quality. Not super heavy duty but with limited use hopefully it holds up. I was a little disappointed to find there is no great way to attach it to the floor from the factory. Going to have to fabricate something to secure it. I also had to order some seat belt extensions. It looks great in there and its very comfortable to sit on!

The day/night shades had taken a beating over the years. I honestly assumed they were garbage. They all functioned fine, nothing torn or broken but stained like crazy, dirty, and nasty. I took the one I had down already from the wall repair and did a test run cleaning one end in the laundry tub with bleach water solution and scrub brush. To my amazement it made it look almost new! Well that meant I had to just do it. I removed the remaining blinds (a project in itself getting them off from behind the valances) and proceeded to soak, scrub, and rinse all of them in the bathtub in the house. It was very tedious but wow it worked! I can't wait to see them hanging again. I have them drying in the shop. I forgot to take before pics unfortunately as you would be amazed at the difference.

Re-installed both captains chairs and buttoned up some loose ends like re-installing the valance. Cleaned up all my tools and misc stuff that had been building up while I have been working in there for the last month. Wow there is so much room now!

MAIDEN VOYAGE!

I wanted to fill the tank for winter. I loaded up the family and drove to a fuel station about 15 miles from me as they sell premium winter diesel and it's cheaper than the local crap diesel by my house. She was thirsty for 100 gallons but it means my fuel gauge is pretty accurate which is great!

It was a bright sunny afternoon and I was grinning ear to ear driving the new toy and could not just go home. I took the long scenic way back and put 56 miles on and could not be more thrilled. It drives REALLY nice. Such a great reprieve from the old E350 chassis class C gasser that I am used to driving. The power of a diesel pushing this 30k# mass of machine up hills effortlessly, smooth, and quiet. I will never go back. Diesel Pusher is my new life and I love it!



What is next??

Interior:
-install blinds once dry
-finish bedroom carpet, new mattress
-clean everything top to bottom thoroughly
-carpet termination at entry stairs
-more things that I am not thinking of

Chassis:
-finish rebuilding HWH pump assembly
-replace drive tires
-inspect braking system
-inspect airbags closely
-speedo is not working
-PAC brake does not seem to be working
-change tranny filters
-service generator

[triplewide]

The Recpro modules I have installed had a metal frames. The frame had a metal angle front and rear. before assembling the pieces, I turned then upside down and drilled holes through these angles. Screwed the sections down to the slide floor (watch screw length).The rear angle was accessible without the backs installed. The front was accessible with the pieces reclined. All three assemblies I have installed had reclining sections. May be different on yours. When my sections were attached , there were holes that aligned at the marriage sides. I used machine screws to connect the sections together through these holes. Made for a sturdy install.

[Joyce M]

You did amazing work. Thanks for sharing!

[nbluesky]

Originally Posted by Joyce M

You did amazing work. Thanks for sharing!

Thanks! It's great to hear feedback, I am enjoying the adventure and happy to share it for others to enjoy as well. I have never posted a project like this online. I am getting a kick out of it

[nbluesky]

Originally Posted by triplewide

The Recpro modules I have installed had a metal frames.

Thanks for the input. Yes this one has a metal frame but is a pull out queen bed so it is a little different. I know I will be able to figure something out. I will post some pics of whatever I come up with. I will probably do it when I put the seat belt extensions on as I will have to pull the sofa out to access the bolts on the floor.

[triplewide]

Could use something like this for extending seat belts:


https://www.amazon.com/Safety-Extend...127171&sr=8-10

[nbluesky]

Originally Posted by triplewide

Could use something like this for extending seat belts:

I went with something similar but all those with the buckle were the wrong size. The HR buckles are wider than the 7/8" that seems to be readily available standard size. What I found were just extensions that add length to where they are bolted down. These will be perfect.

[nbluesky]

This evening I was able to spend a little more time on the HWH leveling system. The tank and solenoids had taken a beating over the years and needed some love. I scarped, sanded, and cleaned everything with acetone. Then I applied my favorite rusty metal primer ever. This stuff is awesome. Rustoleum Rusty Metal Primer. You can only by it in cans for brush on and its nasty stinky stuff but it works! For a quick and dirty paintjob this stuff is great. I might get fancy and top coat with another coat of oil based black Rustoleum as well. I'll see how ambitious I get

The caps on the solenoids are aluminum so I might just leave those. I really wish I was putting all new solenoids on (just replacing one of the four) but at $300 each it's not worth it. It will be kind of ugly but if it levels the RV I'll take it!