Motorhomes are a money pit... There's no other way around it. Once you have so much invested in making it just right for you, something happens. Then do you sell? buy another and modify IT?

We chose to stay with what we had and forget the makeover, we are reconstructing the whole thing.

A little background:
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This is what we bought in Oct. of 03. It seemed like it had what we wanted (no slides), price was OK, and it drove terrific.

Inside was plain, but nice
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First thing to do was beef up the hitch for towing the stacker:
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Of course, this was for sand and we learned that the 19.5 tires sink like disks in the sand and we already knew the dangers of airing down those Goodyear tires!

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towing the beast was no easy matter:

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Finally, we got to camp after REALLY straining things:
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All of this straining really started to take a toll on things, especially the transmission:
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Transmissions are NOT supposed to have convertible tops. This one got way too hot.

Suncoast transmissions (Florida) built us a 4L80e that they said should handle the Job, IF we reduced the tire loading on the drive train:
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The new tranny before installation

tranny set us back about 4k (definitely not for the faint of heart)

Also at this time we added the US GEAR 22% gear splitter box to the back of the transmission in the underdrive configuration. On long grades when towing heavy, this comes in handy.


Also, when maneuvering in off road, having the 22% lower first gear is VERY nice.

What to do about tires?

We loved the G647 Goodyears on the road (a very efficient, low heat tire), but definitely could not air them down (steel sidewalls). The 19.5 hhas a pretty narrow footprint when aired up:
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Also, airing down 19.5's has limited added traction compared to airing down 16's.

We decided to have the best of both worlds and swap tires. Our goal was to do a complete swap in less than 30 minutes to floatation tires for the sand.

We started with 38" Super Swampers, shaved them (less weight for handling in the change) and had custom 10-hole rims made for them:
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For this, of course we needed to upgrade the jacking system. The fold away jacks are too dangerous to lift the vehicle, so we bought jacks and a controller that were roughly twice the capacity (from Walt's). We had to do a bit of welding a fab work:
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But the job came out clean and it is very strong
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front:
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Two years ago we spent a lot of time and effort (but not a tremendous amount of money) working on the roof. It was worth the effort:
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We took things down, rebuilt seams and panels, and finally got it completely sealed.



Last year we started seeing problems with the floor of the coach (it's just waferboard... it gets ANY moisture and it turnes into a sponge) , and we started to evaluate. Buy another? Invest (heavily) in what we have?
We chose the later.

Time to tear it apart.
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We too the whole interior out and found a LOT off floor rot:
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We remove the outside body panels and uncovered aluminum studs (very good... Welded together, not crimped or riveted), but also discovered rodent damage:
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Also removed ALL the basement doors and reset them
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Since we have it all apart, we thought we might as well add some flood lamps for the passenger side.
Later we will have a pic of the installed ones.

Another long time complaint of ours was the wiring. Motor homes are not known for good wiring, so we decided to re-do most of it.
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Now THIS is a man-sized project! And I thought I got carried away with my projects. Good luck on the re-build-it will be truly custom when you are done.

We sometimes question our sanity, but we really like the 1994 Alumalite, absolutely love the way it drives and don't see a better class A platform (P32) out there.

Most of our camping is dry camping, so power (we are stepping up to SIX Trojan T105's and 1kw solar with a 2KW inverter) and water (we are planning on 150 Gal.) will really answer the call.

Great project.

Good job so far!!!

Keep posting pics this is a build

Journeyman- well- knowing you as I do... this project is no surprise!-- looks great though and I wish I was around to see it take shape in person!!

Welcome to the board KV!
Great to have you aboard.

It is a fun project, and I can't wait to be dry camping with all that electrical reserve and all the solar.

BTW, there is a marine DC electric panel with breakers and meters
also, the elec. system has an automatic Gen start just in case things actually DO get low...

I am freaking contractor and wouldn't even dream of taking something like this on..
I wan't to see this thing come together.

I can't even keep my MH washed....

Got the headliner in and clamped on the interior walls to get an idea of what it will look like:
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Here, on the wall to the left, is the solar controller and 110VAC breaker box.
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Up in front, in an easy access and visible location will be the main 12v panel
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Got to get the other photos uploaded... We are making progress... little by little.

Add'l changes:

In the rear, on the right side of the bed there was a raised portion of the floor. It made it a pain in the neck to get around the bed as the bedroom was already very tight.
We found out that the raised portion was there just to accommodate an ABS pipe.
A quick redo of the plumbing eliminated that need so now as you can see the floor is completely flat... A huge improvement.

Also, we are moving the bed back toward the rear almost 12" to give more walking space around the front of it. We should nearly double the walking floorspace in the bedroom.

That's alot of work!

Can't wait to see it finished.

This is the slow part, but exciting. It actually is coming together.

We coated the doghouse with lead barium for both sound deadening and heat insulation before recovering. Top console stayed prettu much the same:Click to view attachment
We are building an instrument cluster for that open hole in the dash that will include a 5K tach, trans. temp. vacuum, etc.
Flat screen TV is mounted on a sliding tray that comes back 18" to expose a driving tray for drinks, snacks, etc.
Also, it is much safer to have (while driving) the TV out of the visible range of the driver.





Rear bedroom got a redo. Bed was moved back about a foot for more room, floor used to have a raised section to allow for a drain pipe. now it is completely flat.
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We never were satisfied with the factory counter tops.
New ones are rolled SST.
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Still working out the details to how finish the electrical (looks wise) on the wall with the cabinetry.
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Bathroom is started, walls in, shower unit, etc. Still a LOT of work to do there.
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We used one solid piece of linoleum from the back to the front (no joints) to help eliminate (reduce) any moisture that might get to the wood floor underneath.

wowsers

Looking good. That is a huge project to you.

i was looking for something smart to say but wowsers says it all, kick arse project that would have to be my day time job for me to finish it. keep the pics coming, farmdog.

We were in the same boat last year when we decided to rebuild my Weekend Warrior trailer. More power to you for taking on such a big job yourself. The best thing is when its done it will be all yours. It looks great.

Need clarification here....


We are undertaking this, but most all the latest work (the reconstruction) is being done by Wayne Butters @ IOWA BOYS in Acton (Near Palmdale). He does restorations and reconstructions... Just what we needed for this project.

Sorry for not making that clear... We could have undertaken this ourselves and done fine, finishing probably in 2020!

Thanks BigSammy. Yeah, it will be set up like we want, and with the alum. frame, should last a LONG time. That is what we are counting on.


Pics to come:
Six T105's located up front
2 Kw inverter on slides with 0000 welding cable to the batteries
Installed marine panel for 12V elec control

Got to this faster than I thought I would.

One of our gripes with motorhomes is the access to the coach batteries.
We decided to mount ours up front so there is easy access under the hood.
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Checking the water on all the cells should be easy.
We do need to double check for airflow to the radiator. Airflow for cooling is essential!

Off to the left in the above shot is the monster transmission cooler from an Allison industrial application. Has its own electric fan.


About 6' - 8' behind the batteries is the 2Kw inverter.
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It is mounted on slides for easy access. 4-0 cable from the battery banks to the inverter


Inside, the slide out TV
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The tray is just a box right now, but will be cut down and cup holders, trays, and other features will be added for the driver and the passenger to use while the TV is in the "drive" position

thanks for doing this, thanks for the ideas, just plain thanks

One more shot...

We were always frustrated by lack of access around the front wheel (checking brake fluid, etc.) so we are making the front fenders lift-able. Plan is to mount gas shocks to hold them up just like a basement door.
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Doesn't look like much now, but you can see the little window above and slightly to the left of the wheel. There is a lot of stuff in there. Now we have full and easy access.

Motor home is in Acton.... starting to be just a bit on edge about all that work going up in flames!

More progress.

Flood lights are in on the right side
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Another view showing a bit of the front
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Still need to work on the entrance door and undernneath
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We also installed a pressure water fill to get rid of that messy gravity fill on the side of the motor home
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Also installing a retractable cable (cord reel) for the shore power

Interior shots:

New upholstery fabric
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Still need to mount up the hydraulic lift table, but the dinette is basically installed
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The electronics for the solar and also the 110 breakers are in the closet.
We need to look at cooling issues, plus, get a remote panel for the Outback solar controller to mount up front
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Weather your doing it yourself or not...this project is just cool. Cant wait to see it all done.

Very cool project. Are you also planning to paint the outside?

So now its time to tackle the bathroom.
Top priority is your bottom.

This is what I am leaning towards (squatting towards?) so far:


SeaLand Toilets


SeaLand Toilets from Dometic - 500 Series - Standard Height
These Sealand toilets from Dometic have many such advantages as:

• All-China Construction: Durable finish is virtually stain-free and easy to clean and the china is nearly impossible to scratch.
• Contemporary Styling: European design features deeper bowl. Available in five different colors to match any décor.
• Comfortable Design: Standard 17-inch height is hip- and knee-friendly (low-profile models also available). Solid wood seat has elongated opening for extra support.
• Low Water Consumption: Efficient flushes use barely one pint (0.5 L) of water.
  Just lift foot pedal to add water.
• Improved Cleaning Action: Rim design improves cleaning action and helps prevent spills.
• Hand Spray Option: Some models have the sprayer attachment for quick rinsing and therefore water-saving, and easy, water-efficient cleaning.
• Easy Installation: The SeaLand Travelers universal mounting fits all standard plumbing.

Thoughts, recommendations, ???

I started a thread asking about this in RV tech... But just in case, posted it here too

Couldn't tell? Bummer.

Actually the bottom (blue) just got painted.
Want to see if we can polish out the top (white) and then possibly, if we have any money left, do some graphics. We'll see.

Looks like the same toilet in my WW. Definatly get the hand sprayer.

I just found this and I am too very impressed! I love project threads like this.

Been a while, but the project is still going. Got some fresh pics.
Cord reel (for shore power) now has it's own compartment so it does not take up basement space
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Batteries are getting wired... Still some cleaning up to do there:
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Inverter is getting connected:
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and internal electric panels are installed:
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I dont think I will buy another motorhome again. Way cheaper to do a remodel as long as the chassis is good.

Cheaper, yes, but not way cheaper. We're going to have 35-40k in the restoration including parts and labor.

But in all this we know that it is exactly what we want. Hard to put a price on that.

Inverter is getting wired:
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Gen is getting integrated into the system with the auto-start feature when the batteries get low
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Solar controller and 110V breaker panels in main closet (not wild about the location, but we'll figure something out):
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Looking forward, the layout is basically the same, but the subfloor, flooring, walls, ceiling and upholstery is all new.
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Up toward the driver, the new backup camera's monitor is visible
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In the driver's area, there is still work to be done (wiring, etc.)
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The engine's doghouse was stripped, coated with lead barium (sound and heat insulation) and recovered.

Looks good! We did kinda the same thing......

http://www.glamisdunes.com/invision/index....howtopic=150164

Nice looking motorhome, OB!
Great thread.

Who did you have do your bodywork?
Did you decide on graphics? Who would do that?

wow! awsome job, i thought about this at the begining of the year. i went the other way, and bought a diferent coach. at the end of the day i didnt get everything i wanted, close but not EVERYTHING. seeing this im starting to wonder if i made the right choice..... beautiful job!

It's a hard call Cap.

Most RVers don't use their coaches like duners do (extended dry camping, heavy towing, soft sand, etc.) Most drive into a camp site, hook up power, water, sewer, cable, etc. and "camp".

We wanted something that would uniquely suit us and wanted to do it without slides. This was our best solution even though we went over budget.

your not alone on the budget, i did the same thing trying to get as close to perfect as i could, and well, me and budgets have NEVER seen eye to eye..of all the things that i would change on my new one, interior color and carpet are at the top, the hard wood and dark colors are the way to go for sure!

Work is going slow, but going.

The remote control panel for the solar was easy to order, but the company I ordered it from (ECO direct) is a nightmare. It has been holing up the project and they kept giving all kinds of excuses why this 'off-the-shelf' (as they claimed) part was delayed.
After more than two weeks, they finally got it on a FED EX truck. Now fed ex says there is something wrong with the address. YIKES!


Meanwhile, some of the details from outside:
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Got the reverse lights painted. Having real reverse lights will be SO nice!



Also trimmed in the patio lights:
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There are three, so it should be plenty bright.
Need to look for low current bulbs

I like those lights where did you get them, brand, price, etc.? I would like to add those as side lights for a little visibility in tight spots at night. This is a great project. Should be time to get out and use it pretty soon.

Walt's surplus RV in Fontana.
They were used, but I think I paid 10 or 15 bucks a piece.

Walt's is DEFINITELY worth checking out.

Hope to pick up the finished motorhome Next Friday, but these projects always have delays