Recent modification

[Ralph L. Fullenwider]

Hello everyone:

Ever have one of those modifications that stays on the list but gets pushed
to the bottom each time you look at it? Yep I had one too,
until,,,,,,,,,,,,,,,,,,,,,,,, Grin

Yeppers, with the help of Ernie and Bim, we pulled the gen set out of Ruff
Diamond for some much needed rear oil seals and while it was out it is time
for a modification to take place.

As it turned out, the gen set radiator was in need of a new core and I was
not ready for that one, but it is monies well spent. While the radiator was
being re cored, I had them remove the fill cap, solder it up and then the
cut of filler neck added to an elbow to be placed in a hose that was to
become the highest point fill.

While that was being worked on, we took the Perkins off of the bottom plate
and made it to a car wash for a little, or rather allot of high pressure
washing. Then the fun began in earnest. The high motor mount was removed
with a grinder blade and cold chisel allowing lay out work to be done to
the plate for the modification. After finding a good small independent
welder, it was, load the plate up and off to the welding shop it goes. The
plate was marked, leaving the angle iron supports in tact under neath the
plate. Then holes cut out and a frame work welded in place and a expanded
metal covering welded under neath to protect the new radiator. Yes, we are
doing the cooling system fan modification, by laying the radiator down and
getting rid of the old 1 hp motor and car fan, (loud noise) then adding the
same quieter squirrel cage fan that is in the PT's.

And with the plate at the welders, the radiator at the shop, it was time to
address the rear main oil seal that started leaking like a sieve. So off
came the Kohler end bell, (found the rear bearing about to go)(replaced it,
it was a good timing find) then the field housing was off and rotor off and
set aside. A few more housing pieces and we were there!

It was fun (NOT) when 2 of the 4 over bolts snapped off and it was quite an
undertaking to get them out so they could be replaced (obsolete of course,
so an aircraft all thread was used) As it turns out most of the Kohler and
much of the Perkins are cast and heavy industrial grade aluminum. Steel
being threaded into that usually seizes up pretty bad. Thankfully another
local Birder and friend had a full size mill and lathe in his work shop.

By the way, all of this work was going on in Ernie's driveway on pallets.
LOL But air tools patience and, allot of "oh hell," went into this project.
With the new rear seals in place and engine propped up on blocks on the
pallet, and while waiting on the radiator and welding, I insulated the gen
set compartment and removed, cleaned and lubed the rollers for the tray.
One was frozen on the bolt shaft, no wonder the tray was hard to go in and
out.

Also did some work on the travel lock after a high pressure wash. Things
were now starting come together now as parts were being finished up and
returned to the driveway. We furthered the modification by using the
original shield for the old fan by cutting it down, bolting it together
then bolting that to the original brackets on the radiator and this gave us
an air box to mount the new fan base to.

So with a little mod here and a little mod there, it was time to re mound
the engine/Kohler back on the bottom plate, then re locate the old high fan
motor mount for the two fold purpose of holding the control box and the
side of the mount became the gen battery mount as well as one complete
unit. The side slide plates were re installed, wiring and fuel lines moved
out of the way, Ernie picked up the bottom plate with all things loaded on
it and still on the pallet, with a borrowed fork lift with Bim and I
guiding the unit back into place and bolting it up. Whew, this things
starting to look like something! (is it wine time yet?)

All wiring back into place, dry in and out runs made and modifications made
to help that out, I refashioned the original brackets that once held the
radiator up right and held the compartment door to the sliding tray. This
puppy is really looking gooooooood now!!!!!

Time to fire it up, yep starts and runs the first time (of course, wink!)
Fan runs with the modification from 220 vac to 110 vac and the air going
through the radiator is deflected back toward the center of the Coach. With
the compartment closed we could actually stand by the gen set, with it
running, and talk in normal tones, WOW what a difference!

I still have some items to finish up with, but that is for another time as
the gen set is now ready for service and quieter both inside and out.

I will post some photos of the mod in the files section, but first a few
kudos to Ernie and Bim Burt for the fantastic help with this modification.
Thank you's also go to Randy and John for posting photos of John's gen set
mod of which ideas were borrowed but put to use on mine with different
twists and a beefed up bottom plate.

I am now ready for Blue River this winter for trout season! woo hoo!

Safe travels,

Ralph and Charolette Fullenwider
"84FC35 "Ruff Diamond"
Duncan, Oklahoma