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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 First379 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]


The immediate engine area has now been relined. One large piece remains to cover the left firewall and the remaining roof area.

Adding the liner to the roof section required some ingenuity to ensure tight attachment to the roof as it is difficult to hold the panel up, drill holes and rivet it in place by yourself. So a floor jack was used to press up on the panel. To do it where stuff was in the way of the floor jack, a lever system was used to reach to the side and into the corner.

Now the aluminum liner has been installed on top of the foam board and the FatMat. The combination of the three layers will reduce sound and heat levels inside the coach.

I have prepared this small section for the aluminum liner by gluing 1/4" thick small cell foam board on top of the FatMat.


Here is the largest of the five 1/8" thick aluminum panels that will line the engine compartment. If you imagine it rotated 90 degrees toward you then lifted up it will line the top of the engine compartment and most of the left wall and a little of the right wall. It will be the last one installed. See the two prior photos.

Looking the other way. Virtually all of this will be covered in 1/4" foam board and then five 1/8" aluminum panels will be used to reline everywhere you see the FatMat.

This is a nice and clean engine compartment. Putting the FatMat on around and over the areas with pass-through fittings and standoff pillars kept the installation challenging.

The FatMat installation is now complete. The uncovered sections on the lower right and left will not be covered as they do not lead to the interior. The propane tank is in front of the section on the right and the gas tank the section on the left.


The FatMat will be installed on all of the surfaces that adjoin the interior of the coach which is everything except a section on the lower right and lower left. This will be covered with 1/4" of small cell foam board and then that will all be covered with a new 1/8" lining of sheet aluminum. There should be a major reduction in the engine and fan sound levels and a reduction in heat soak of the interior when stopping after a day's drive.

Here is the TURNING POINT! While a few more things are still being removed, here is the first new thing being installed. I have started the installation of the FatMat sound suppression material.

Here is the pair of Perma Cool coolers that have been removed. One was for the transmission and the other for the engine oil. They are the tube type with fins and were located under the propane tank behind the mud flap. I do not think they were very effective. The transmission cooler will be replaced by a stacked plate cooler in a different location with better air flow.

Almost everything is out. Cleaning up some wiring and then relining the firewall will start.
Show Newest Photos First | Show Oldest Photos First379 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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