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Rebuild Begining Middle End


REALLYRURAL

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Been spending time going through 10 plus years of Digital Photos of various projects I have done.

The 1991/1992 Warrior while still a work in progress is well worth sharing with others.

 

A few pictures to start with then I will add more with some commentary..

 

When I purchased the 1991 it had just come from an Insurance auction.  It had been declared a total loss from an encounter with a pine tree.

There was a branch 5 inches around driven through the floor just missing the fuel tank. It had staked the rig to the ground and someone had used a

chainsaw to free it from the ground so it could be towed away.

 

 

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When I picked this up at the salvage yard the transmission was slipping in forward as it had been towed in neutral from where the tree fell on it to the auction then from the auction to the salvage yard.

Towing in neutral cooks the forward clutch pack as it has no lubrication and this clutch pack is the only section that always turns with the output shaft (more on that later).

I flushed the transmission and added some Lucas to it and got it working again (it may well have kept working if I had driven it every day after. But it was parked for over two years before put back on the road}.

 

Upon getting it home I tore it  apart to inspect and assess just what I had gotten what myself into.

 

AC unit was trashed, I cut the roof just about 2 feet forward of the bathroom, I still find pieces of the broken windows, door frame badly bent, ..

 

Turns out what had been a nice looking Toyhome (61 thousand miles) that had been cared for and just had an insurance claim and been through that process. It had just as much rot behind that vinyl wallpaper as

any of these you find.

 

The overhead had extensive rot and needed a rebuild even before the tree fell on it. The rear wall in the bathroom was the same. 

 

Leaks around the openings in the ceiling had compromised the wood in that area.

 

 

Before the tree fell this rig was a nice looking rig that anyone who did not know to scratch the surface would be really excited to purchase.  The systems all worked, super clean, maintenance records, new tires, no rust it had

everything one could want and would have gone a few more years before the rot really got the best of it.

 

Point is that any 20 year old camper is going to have those types of issues.  The original owners purchased it to go camping and did not know how water gets in through every nook, cranny and screw hole.

 

After tearing it apart I went looking for new windows and started rebuilding the skeleton. 

The skeleton is aluminum extrusion 3/4x2.  I found that Tractor supply in their junk pile has a constant need to dispose of 3/4 x 2 steel extrusion and will give me all I want (something is shipped in the framework).

 

I lucked out and found some used windows at a place in Chelsea Maine that had just opened as a new and used RV supply. 175 bucks for the windows.

 

More later.....

 

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The clutch pack is not engaged how ever flat towing produces no lube to any thing inside and some parts still spin, the same is true for a manual in neutral not advised for any distance with the drive shaft still connected on any vehicle!

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On 2/2/2022 at 10:04 AM, Maineah said:

The clutch pack is not engaged how ever flat towing produces no lube to any thing inside and some parts still spin, the same is true for a manual in neutral not advised for any distance with the drive shaft still connected on any vehicle!

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This is not where I want to go with this thread but I will explain the transmission for you.

 

The output shaft (part number 678) is driven by the driveshaft.

 

The only thing directly hooked to the output shaft (part number 678) is the forward planet (part number 582 the third picture from the left shows a  picture). The forward planet (582) is on a spline on the end of the output shaft (678) it is locked on with a cir clip (part number 694).

 

The forward planet (582) spins the forward ring gear (592 the picture all the way to the right) which spins inside of the the forward drum (part number 554 fourth picture from the left) that holds the the forward clutch (part numbers 126 and 106 make the forward clutch) The forward clutch is held into the

forward drum by a Cir Clip (part number 876)..

 

When towing in neutral the only thing affected is that forward clutch assembly and it burns up from lack of lubrication.

 

Here are the pictures of mine.  It is the only thing I replaced to get the transmission up and going 10k miles ago.

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Back to the rebuild.

 

My first attempt at rebuilding the roof was using 1/4 plywood. I made side to side support with 1x2 oak and glued and screwed together. It did not look bad but I had to travel out of state for work so I covered it up and came back a year later.

 

Upon starting again it was obvious that picking up where it was left off was not an option.  Enough moisture had got to the 1/4 ply and other plywoods used to make them moldy and de-laminating..

So I tore everything out and choose pvc boards and panels for everywhere wood was before except for structure like the top plates on the wall.  I used pressure treated 5/4 decking held on with3 inch long by quarter diameter deck screws I picked up at Fastenal great screws.

 

I used aluminum channels for the side to side roof support. I built it so that I can stand in most places on the roof and can add more strength down the road.

 

I was going to use the original filon on the overhead and front but backtracked on that and went with pvc everywhere on the roof except the front.  I used 1/16 FRP there and it worked out well and was easy to make the curves.

 

The camper wall on the drivers side is tongue and groove pine and has worked out fine. If I was going to do it again it would be pvc panels then select out of the millions of patterns of wallpaper for a finish.

 

I screwed and glued the roof. I used a marine adhesive that has held up well.

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  • 3 weeks later...

Your personal attacks on members of this forum is unacceptable and unprofessional. Additionally, some anger management classes would be a good thing at this point.

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  • 7 months later...

Fred with all due respect.

 

I consider it a personal attack on myself to have a moron or multiples of morons question hard facts of how an automatic transmission works when I have rebuilt hundreds of automatic transmissions and have tried my best to provide a guide that will help members of this forum.

 

I was trying to provide a how to with pictures.

 

Others just provided nonsense.

 

What can you provide on the subject?

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On 2/22/2022 at 9:06 PM, fred heath said:

Your personal attacks on members of this forum is unacceptable and unprofessional. Additionally, some anger management classes would be a good thing at this point.

Allow me to personally attack you Fred.

 

Your a  eeeeeee moron and have helped a hijack a very nice informational thread. You suck and have added nothing to the coversation.

 

Maybe you have no skils to offer?

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On 2/6/2022 at 3:16 PM, REALLYRURAL said:

I was going to use the original filon on the overhead and front but backtracked on that and went with pvc everywhere on the roof except the front.  I used 1/16 FRP there and it worked out well and was easy to make the curves.

 

The camper wall on the drivers side is tongue and groove pine and has worked out fine. If I was going to do it again it would be pvc panels then select out of the millions of patterns of wallpaper for a finish.

 

Hello REALLYRURAL,

I hope you are still available for this thread. I have questions on the area of your overcab roof and sidewalls. I am just at the point where I need to cover my overcab sleeping area. I am hoping you can answer a few questions for me please.

1.  How did everything hold up for you up to this point? 

2.  I am having issues trying to find the pvc and PRP boards in my area (Okanagan Valley, British Columbia, Canada). Is any of this material corrugated, or is it a flat thin sheet?

3.  Do you have pictures of your final result of the overcab rebuild?

4.  Did you just use a knife to cut these types of plastic sheets?

Thanks for your time on my questions.

Leslie

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2 hours ago, linda s said:

I don't know what he means by PVC, that's usually pipes not flat sheets.

Linda S

Nope, PVC does come in a sheet.

https://www.homedepot.com/p/1-2-in-x-4-ft-x-8-ft-White-PVC-Sheet-Panel-190360/205079515

 

 

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Hi guys and Linda,

I will just replace with the lauan plywood. Found some in my hometown. Thanks for all the input and help. Linda I am also a "she .. with the male spelling of my name" LOL.

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  • 2 months later...

The pvc products I used on this project all come from home depot and Lowes.

PVC now comes in 4x8 sheets 2x8 sheets of different dimensions.  It also comes in 1x1 to 1x12 in many lenghts.

 

To do the forward end of the cab overhead I used a FRP (fiberglass reinforced plastic) sheet that is normally used in bathroom walls or other wet locations. I made the bends very easy to do and has held up very well after 20 thousand miles.

 

All the wood was replaced with pvc 1x whatever was needed. except for under the roof I used 5/4 pressure treated decking.  The wood at the bottem of the skirts was replace with pvc and glue with a marine adhesive.

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