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The Dieselfication of Coach 1046

Author: BigRabbitMan (Show all albums) This album is dedicated to following the process of Coach #1046 being converted from a 1976 Chrysler 440-I with a 4spd Allison AT540 transmission to a 2006 GMC Duramax LBZ turbo diesel with a 6spd Allison 1000 double overdrive transmission. There is a companion discussion thread in the Mechanic's Corner section of the Forum area of this site.

Show Newest Photos First | Show Oldest Photos First 379 Photos - Page : [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] [22] [23] [24] [25] [26] [27] [28] [29] [30] [31] [32]
Here is the driver side bracket. This one presented a more challenging situation to design a means of supporting this side of the engine as the bracket was in midair with nothing closeby. To provide proper support to the engine and not get involved in esoteric solutions, we went with strong iron! A 1&1/8" plate will be inserted in the gap that you see. It will be anchored by the same four bolts that will be securing the crossmember that was removed and attaches to the verticle plate on the left. The plate will then extend back to where the engine support bracket is which will then be welded to the plate. The crossmember has been redesigned to allow for the plate and to go under instead of in front of the engine. That will keep the area at the face of the engine open and free for radiator mounting designs.	Meanwhile at the top of the engine, the air intake was replaced on the engine so that proper engine height can be determined. Two things were determeined. The first is that the engine can go up another inch or so. The second is that the engine compartment wall will not interfere with the air intake system. The air goes in here and down into the turbo then out the other side and on to the intercooler.	Meanwhile, back inside the bracket for the fuel pedal was completed and the pedal installed. The pedal has the curve in it as in the donor, it needed this curve because of the mounting options combined with the transmission tunnel.	Another view showing the lower bracket and pedal position.
Back outside, this is the rear crossmember that has been cut into three pieces. The center section, which contained the motor mounts for the 440, is going to be replaced.	On the left is David S., my nephew, who is an electrical engineer. He is going to be designing and building the control module for the pusher fan. The fan has a viscous clutch and will have its degree of engagement based on engine temperature. The fan will start engaging at 190 degrees and be fully engaged at 220 degress. By only engaging the fan as needed, fuel economy will be improved.	Here the center section of the new transmission mounting crossmember is being drilled.	Mark is attempting to remove the last of the wiring harnesses from the donor pickup. It was easier to remove the dash and then work on it that attempt it inside the pickup.
Here is the steering column. It will not be used at present, but is being kept just in case it is decided to change out the steering columns or we need to refer to it when wiring the body control module into the coach.	The last item comes out of the donor. The rear end will be sold to help recover some costs.	This is the floor in the coach at the rear of the bedroom. In one of the test fittings of the engine and tranny, it was determined that the transmission needed to go slightly higher than the floor would allow so ....	.... Mark got the sawzall and went to work.
Show Newest Photos First | Show Oldest Photos First 379 Photos - Page : [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] [22] [23] [24] [25] [26] [27] [28] [29] [30] [31] [32]

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