Generator and Gen. Bay Rebuild

[Joe Camper]

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Here we go again. A forklift is the preferable tool for this job but if you're very careful you can get away with a tractor as small as this this thing was just barely big enough to pick up one end and then the other. I just took my time and went back and forth and blocked it up till it was high enough and I got her into the back of my 1ton van.

This was a great thread to revisit for this project. This gen has 20 some thousand hrs on it. Still made good reliable power. Wanted to get a bran new one and use this for backup at the lodge.

Nope.

It would of had to be destroyed and an afadavid signed with pictures showing a hole punched in the block at the serial number along with the rest of the documentation or u can not get the same replacement.

Any outright new purchase of a gen this big will be one with a catalytic converter and meeting current emissions standards.

This one is getting rebuilt at the original manufacturer. Engine power source Rock Hill South Carolina the warranty it just the same as a brand new one it's getting a brand new head but this engine block will be rebuilt with new parts.


I'm going back to Sundown for the bay insulation I've used them on all the gens I pull since I first did one on my XL.

That'll probably be 3 weeks turnaround time but when I do get it back and I start reviewing a day I'll throw a few more pictures up that sound down stuff is the best stuff out there everybody likes it. The old stuff that's in there is just crumbling away lot of buses out there just like it too.

[Joe Camper]

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Just a bit tatty.

[Joe Camper]

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Here is what I was handed today when I picked up this generator. It should be an interesting read for all.

It's less than estimated they turned it around in under 2 weeks. Has the same Warenty as a new replacement. We will see how it runs.

I was handed the old head it's either a 17.5 or a 20, it's still good. Wasn't even disassembled they separated at the flex plate and the bellhousing and those 10 or 12 bolts comes off one piece. Anybody want it? I might make yard art out of pieces.

This came out of Senators conversion their Entertainer coaches. They're out of Florence Alabama they know how to build a conversion the manufacturer of the generator that they put in this bus in 2002 is still down here alive and well. it's a huge place in South Carolina.

Gadget guru if ever in the vicinity stop here,bet u would spend the day.

Hope u r all having fun at the rally. I just drove up I-77-N through west Virginia. 4 thumbs up for the West Virginia Turnpike, great Drive.

[Joe Camper]

Here is what I uncovered as I began the process of reinstalation. 2002 XLII

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Expected pile of funk, including mouse nest.

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Unexpected. The front half of the weight of the gen rests perfectly between 2 framing members and the floor was on its way down. Already a 1/2 in down. It was snagging the outer bottom lip of the bay coming in and out and that's why.

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Unexpected to see how generally soft and rotten the entire floor has gotten.

[Joe Camper]

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I will put 3/4 pressure treated paint it prevo grey and put this plastic tray back in. I bet if it weren't for this tray that floor would have been even worse, it probably saved the day the wood floor now pokes very soft.

If u pull the floor gently u can do it without disrupting the prevo spray foam underneeth, this is a big plus IMHO. The finished product looks like it had never been touched.

When was the last time u poked around on your bay floors? This usually shows up in the plumbing bay.

[Joe Camper]

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As rotten as the floor was it did not separate from the spray foam on the bottom. Have to reput.I'm going to drop 2 pieces of angle in between the floor frame where the gen end sits so even if the floor rots again it will be sitting on iron. The demo is about done this is as much of the floor as I'm repairing.

[Joe Camper]

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3/4 in plywood pressure treated is not available in full sheets so I used a couple pieces.

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Didn't matter because I was adding angle to the structure to better support this end of the gen.

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I plowed out the bottom of the ply at the angles so it would lie flat and painted everything grey.

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Countersunk self tapping #14 metal screws.

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Some filler to fill in the heads and seams.

Runnin out of daylight but that's mo betta.

[Joe Camper]

So this thread becomes bay floor repair for a while.

Patching a bay floor at the threshold for the door and doing repairs at the center of the bus r 2 very different projects. Usually by the doors is where the rot starts and that's fine with me if u get my drift. Sometimes in the middle u need to use other methods.

As I was scrubbing and prepping for paint and glue the floor under the other end of the gen I initially thought I could work with became really evident I need to fix it. The weight sits very close to the frame but not right on it, the wood is solid but the picture shows how how much it is sagging.

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I took a router and plowed out the floor from the inside to drop some channel in flush. It's just long enough to span the gap over to the next frame member. Taking this additional floor up...........your call. I'd do it if asked.

I'll plow another one in for the last corner and lay the plastic mat on top it will be stronger than new.

[Joe Camper]

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Now we have a bay floor capable of carrying a generator.

Some of your bay floors on some of your conversions were beefed up with additional support buy the converter some where not, this one was not.

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Now it's on to the insulation. Soundown company. Good stuff.

[Joe Camper]

Now that I had a chance to pull a second liberty generator out I think I got it figured out.

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Those wonderful Folks up in North Chicago had the foresight to put enough lead on the generator that you can take it completely out of the bus and put it on the ground right next to the bus and the only thing I had to unhook was the exhaust.

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I didn't need to sling it with chains and use spreaders and have to deal with no clearance at the top like there isn't either. Led the generator out to the stop far as it would go and then just slide the forks right underneath it like sliding the spatula underneath a pizza. Remove the stop back the fork truck up 6 or 8in and lower to the floor. Maybe a couple hrs of work to get to this point.