Race Deck Projects

Nick Badame Refrig/ACC · January 20, 2010, 12:50:18 PM

Hi Guy's,

Just thought you guy's would like to see my latest projects.

This is the first deck of 3 to be built and most likly this is the hardest since it has roof airs in the way..

The next two have basement systems.. [ 01' H3-45, & 99' XL are next]

This coach belongs to Star Coach Race Tours, it's the same 03' H3-45 I had here in September for

a complete Webasto install. This deck's sub structure is constructed out of PT 2"x 4" with custom

steel brackets attached to the crossmembers. It will have a composit [brown] decking surface and

1"x 42"H, 2 tear aluminum railing system. All the railing hardware is from KEE KLAMP.

Decks are 24'x7' and custom grated covers will be constructed over these a/c's and used as tables.

http://www.starcoachracetours.com/Home.html

Nick-

Jeremy · January 20, 2010, 01:21:50 PM

That's very interesting...I'm planning a roof deck for mine, although only for about a third of the length of the roof. Mine will be made of steel with a Tek-Dek type surface, and I'm making the outer edges fold into the centre so no part of the deck can be seen from the ground when it's not being used. It'll also have a fold-up bimini-type top over it, and possibly removable sides as well - I have an idea that in warm weather it could almost be used as an extra room for eating, reading or socialising.

With the ones you're doing, how will people get up there - ie., an external ladder or roof hatch etc? Also, how will the side railings be attached to the deck? The forces on the attachments at the base of the railings can be enormous when someone is leaning against them.

Jeremy

belfert · January 20, 2010, 03:29:25 PM

That is a very different way of building a roof deck. I have seen most made of aluminum or stainless.

Isn't it awful heavy with PT wood? PT is usually almost dripping wet and heavy when new. I've always wanted a roof deck and this could be a good way to make one for less money than a metal one.

philiptompkjns · January 20, 2010, 04:03:23 PM

that is an AWESOME project. Please post updated pictures for us :-)
I had something like this in my imagination, but yours is better.

Are you worried about hurting the roof a/c's efficiency by bocking its ventilation around the edges? I'm sure you thought of that though.

Nick Badame Refrig/ACC · January 20, 2010, 05:38:40 PM

Hi Guy's,

What you are seeing in the second picture is the main PT supports that are lined up with the 32" on center

sub steel supports that are under the the bus roof. Tomorrow, [day 3] we will be adding 16" on center PT

framing that will be supported off the 32" on center structure and not in contact with the bus roof. Also, you

may notice that the outer 2x4's will be 2 1/2" in from the sides of the deck. This is for extra support for the

railing structure's base mounts to anchor to. The very most outter sides of the deck will be skirted with brown

decking material for a finished look. Then the composit decking will be the last step. The finished height of the

deck will be 4" below the top of the a/c's for clearance purposes. The dometic penguins vent at the lowest

part of the upper unit which has access to the under clearance of the structure.

Keep tuned in, I'll post more pics as it comes together.

Nick-

PS, below are examples of the Kee Klamp railing hardware.

Chopper Scott · January 20, 2010, 06:57:44 PM

Pretty cool Nick! Having plans in the future for some Nascar races I see the need to do something like that. I'll be watching your progress and hope you keep showing us pics. When you get done give us a "hindsight is 20/20" commentary to help us out.

NewbeeMC9 · January 21, 2010, 02:42:58 AM

Have you considered the vinyl decking material? That dark composite stuff can get mighty toasty up there. Of course the bright white vinyl can help burn the bottom side of the beer belly too

. And the Vinyl is pretty light.

Pretty kool project!!!

Zeroclearance · January 21, 2010, 09:00:44 AM

Nick I have two questions..

Can we see how your Webasto install looks in the Prevost. Snag some pictures for us..

2nd.. Are you using and grommet or sealant between the aluminum roof, and you brackets that you are screwing into the roof supports. What I am getting at is>> with people walking on the roof, the load gets placed on the brackets (there is motion and movement). In construction terms are you hot mopping around the brackets prior to getting the decking installed?

I like many others are looking on with great interest.. Good luck

BG6 · January 21, 2010, 10:50:02 AM

Quote from: Nick Badame Refrig. Co. on January 20, 2010, 12:50:18 PM
Hi Guy's,

This deck's sub structure is constructed out of PT 2"x 4" with custom

steel brackets attached to the crossmembers. It will have a composit [brown] decking surface and

1"x 42"H, 2 tear aluminum railing system. All the railing hardware is from KEE KLAMP.

Decks are 24'x7' and custom grated covers will be constructed over these a/c's and used as tables.

I thought about doing it that way, then discared the idea. You are getting on the wrong side of the strength-to-weight ratio, compared to using a steel or aluminum substructure, plus adding a maintenanca issue (how will they paint the wood every year?) AND adding several square feet of built-in headwind.

When I get around to doing mine, I will buld a steel or aluminum frame, attached to the tops of the pillars. Using 1-1/2" x 3/4 channel, I will have solidity, good weight transmission across the entire frame and into the entire coach (retaining the monocoque stress distribution) and be in about the same weight range (if not lighter) than the wood and plastic deck. It will also mean no weight on the roof.

My rails will be hinged, with the side rails like those on a hospital bed, carrying the front and rear rails with them, so setup will be simple -- park, climb up the front hatch and lift the front half into position and lock, then go to the rear and do the same there.

TomC · January 21, 2010, 11:30:58 AM

Nick- I know you're the A/C expert, but the venting of the Penguins with it's squirrel cage blower requires around 6 inches of clearance space on that side of the A/C. I don't see that kind of clearance. And if it blows under the deck, it will get super heated to the point that the A/C's won't breath (but then you know that). It might be advantageous to move that 2x4 about 6 inches away from the exhaust of the A/C's. Good Luck, TomC

belfert · January 21, 2010, 01:15:47 PM

Why would PT wood need to be painted?

Nick Badame Refrig/ACC · January 21, 2010, 02:05:13 PM

Hi Tom,

The customer has been informed about the clearances months ago... We will see how that pans out this summer.

Hi Zero,
I will post the Webasto pic for you.

I don't have much time to write now but here is another pic.

Nick-

Nick Badame Refrig/ACC · January 21, 2010, 07:18:35 PM

Hi Zero,

My custom steel brackets are sealed to the roof with Di Core which is a RV roof sealant.

The steel brackets are connected to the bus crossmembers with 1/4" thread cut machine screws. [45 mounts]

Tomorrow the composit decking will be pilot drilled and screwed down and hopefully Saturday I can start the railing system.

Nick-

Dreamscape · January 21, 2010, 07:40:10 PM

Are you going to have a toe kick?

PCC · January 21, 2010, 08:41:17 PM

Is a toe kick something to assist you when you get too close to the edge and find it as an incentive to fly?

My question is 'Is there some kind of protective railing or a chain that can be placed around the edges of this deck to prevent such a mishap?' What do you plan for this? I am curious.

Keith
PCC