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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]


Back inside you can see where the original gauge cluster was removed.


Here is the generator on a pallet awaiting conversion to propane. I need to thank Bunthan, Larry and Mark for their assistance in extracting and moving the generator as it weighs 290 lbs. The parts needed have been ordered and should arrive in about 3 weeks.


The generator has been removed. This will make working on the engine installation easier as it has opened up this area.


Just below and adjacent to the transfer switch is the auxillary generator. Because the engine fuel is changing from gas to diesel, this unit will no longer have a source of gasoline. It will be removed and be converted to run on propane as the coach has an onboard propane tank to fuel the central heat, water heater, etc. and that same tank can be used to fuel the generator in addition to the "house" needs.


This box contains the 110 volt transfer switch. The coach's source of 110V current can be from either a heavy cord plugged into an outlet or from the on board generator. The box was dismounted when the engine bay was relined and has now been remounted. The black cord is for landline power and the flexible conduit leads to the generator. The switch inside the box transfers the coach's system to whichever system is live. If both are live, this one selects the generator. They can be set up either way.


The fuel pickup assembly is now installed into the tank. The blue cap will be replaced by a permanent cap as this is the tank vent that will no longer be needed as the FMC tank has a very short fill spout. The orange cap will be where the fuel pickup line attaches and the red one is for the fuel return line. Fuel injection systems circulate fuel to the engine and back on a continuous basis.


The flange is now securely mounted to the tank.


The ring on the right will go inside the tank. The holes in it are threaded to accept the 20 ea 10-32 SS bolts that will clamp everything together. The ring is sliced in one spot so that it can be inserted into the tank. Note that before assembling everything, the inside of the tank was wiped clean to remove any acccumulated dust and metal particles.


(2 Comments)
Here is the mounting flange that was removed from the top of the donor truck fuel tank prepared for mounting to the top of the new tank. You can see the nitrile gasket that will seal everything to the tank when it is flipped over.


Then sections of fuel grade hose were added to the fuel pickup and fuel return lines to bridge the gap in them. The same will be done with the electrical wires for the fuel guage. Napa fuel pump wiring kit #888536 provided the wires and McMaster-Carr supplied Raychem part # DR-25-1/8-1x6 which provided the diesel resistant shrink tube. I have elected to not change the length of the fuel gauge float arm. That just means that the gauge will read the bottom half of the tank, which is the important half!!


The rods were inserted into the copper tubes and then the tubes inserted onto the original rod ends. Since the assembly is under compression, I then just squeezed the copper tubes at each end with a Vise Gripe pliers so the new assembly would not fall apart when not under compression.


The pickup end (on the right) is pressed against the bottom of the tank by springs embedded into the bottom portion. The springs push on the two rods. I created two 10" rods (the additional depth needed) and two longer copper tubes to hold the rods in place.
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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