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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]


Here you can see how I sealed the shroud to the radiator on the inside. I used some left over FatMat (see lining of the engine compartment in earlier photos) as it has pressure sensitive glue that sticks very well and is very flexible.

The top and sides of the shroud were relatively easy, but the bottom took sigificant sheet metal adjustments. It was due to the combination of the support brackets and the low position of the fan on the engine. The fan is low on the engine partly to allow the front of the hood of the donor pickup to be lower for less wind resistance.

The angles at the bottom are to clear the support brackets.

The fan shroud has now been completed.


The front 4" of the fan shroud was able to be fitted outside of the coach, but due to the varying dimensions and angles, the side pieces are being created in the coach. At this point the radiator will be posistioned, this part taped securely to the radiator and then the whole unit removed. With it out, the top and bottom pieces will be added and everything riveted/bolted together.

Here is the longer right hand side stepdown bracket.

This is the same mount as seen from below. Note that the stepdown bracket is bolted to the original radiator bracket that was used with the Chrysler 440.

This is the left mount as seen from above.


The radiator is now set on its mounts. It is the Ford radiator for the 7.3L Powerstroke diesel as the dimensions fit better than the Duramax radiator.

This is the right bracket. Note that it is longer than the left one. This is because the engine in the FMC is angled to balance the coach weight left to right as the auxillary generator is on the left. I have chosen to line the radiator up with the rear cowling and not the engine. This helps put distance between the pusher fan and the radiator.

The fan on the Duramax is lower than the fan on the Chrysler 440, so it is desireable to lower the radiator. It is also desireable to have the radiator as far away from the fan as possible. for those two reasons the step down bracket was added to the original radiator bracket. This is the left one.

The exhaust pipe that was shown earlier is at the left end of the muffler. The muffler will be suspended after the rear cowling is in place as the exhaust outlet needs line up with the hole provided in the cowling.
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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