Cutting out stuff in AC bay of 4108.

[Chaz]

OK, here's the deal... I want to put the electrical stuff - batteries, inverter, generator, etc. - in the AC bay of my 4108. That seems to be the usual and customary place. But what can I cut out of there and not hurt the structural integrity of the coach?? Or does it matter?
  By the way, cutting and welding aluminum is no problem if someone has a suggestion how to cut out whatever and then reinforcing it back to get more room.

   Thanx guys,
       Chaz

[Jerry Liebler]

Chaz,
     You've seen mine, I believe I've taken out pretty much all that it's safe to take out.  You may want to rotate the main air tank, as I did, putting it on the compartment's rear bulkhead.
      Have you got the condenser, evaporator, heater core, blowers etc. out?  After them there is lots of ductwork that's obviously of NO structural significance.  The angles on the bulkheads that he condenser mounted to can be removed (de riveted) the ones the condenser fan mounted to also but they may be useful as a base for whatever goes where the condenser was.  I believe the aluminum piece between the bulkheads, that separated the condenser compartment from the center where the evaporator, heater core and blowers were, is structural so I left it alone and ended up using it to mount the step up transformer for my front AC.
Regards
Jerry 4107 1120

[Chaz]

Thanx Jerry! And thanx for the call!!
  Hopefully tonite i can get in there and do some "guttin".
  I also ordered 8 of the Exide GC2-H batteries (Apparently what you called T105s)  , 480.oo before tax. (OOOooooooo, that stings. But a good deal, i guess)
   Now I have to start figuring out how to do the wiring.    I'll probably be callin ya! 
   Thanx,
     Chaz

[FloridaCliff]

Chaz,

All of what Jerry said and if you have access to one I would pressure clean the you know what out of that area first.

That was probably the nastiest part of the destruction phase, and I am not shy to dirt.

I built the frame for my slide out generator on the drivers side and meshed over the old fan area.

Should help with air flow in that compartment.  I have dual 24vdc blowers to push air out.

That is a nice area as you have two access panels built in by GM from the bay.

I would terminate the wires in the a/c bay to a terminal strip.

I have reused several, and they go to the mid distribution and the drivers control panel.

Good time to fill those old ducts with spray foam and block off any ingress points for generator smell and carbon monoxide.

Save your heater coolant pump, if you don't want, lets make a deal.

There are also a/c lines and heater lines you will have to cap off or make some decisions before you block everthing up.

Good Luck,

Cliff

[Chaz]

Thanx Cliff.
  I already sprayed a can of Gunk in it and used a small pressure nozzle on my hose to get it clean enough to even consider crawling in there to start cutting things out.  yuck.
  Jerry Lieber has been helping me -over the phone- on how to go about putting 8 batteries, my inverter and a generator (when I can afford it) in that bay. Slide outs are definitely a high priority!!
  Not sure what you meant by this:

I would terminate the wires in the a/c bay to a terminal strip.

I have reused several, and they go to the mid distribution and the drivers control panel.

But I'll probably figure it out when I get in there. ALL that wiring is a little overwhelming!! But I still retain a little left over electrical knowledge from the Navy. (very little!  )
  I think the heater coolant pump is already gone as most of that compartment is empty.
 
  Thanx again,
       Chaz

[Dallas]

Chaz, I don't have a lot of funds, r a lot of skill in fabrication for that matter, but I built my battery slide out from bed rails and the wheels off of roller skates.
I originally built it to hold 2 8D batteries but since have modified it to hold 6 grp 31 deep cycle batteries.

I used 10 roller skate wheels on each side, figuring that the rubber wheels would allow a bit of cushion and that the bearings in the wheels should be pretty heavy, considering some of the 300+ pound roller skaters I've seen.

It slides smooth enough that I can pull the tray with 3 batteries out with one hand.

Dallas

[Chaz]

Sounds cool, Dallas. Good improvising. To me, thats fun!!!!!!!!
  I have some old conveyor stuff, etc. from when I had my fabrication business. Good thing I'm a pack rat!!  LOL  I think I have something that will work. If not, I'll start looking at chasing down kids with roller skates!!!  LOLOLOL    (WHAT!?!? You think I'm kidding??? LOLOLOLOLOL  )

  Chaz

[Chaz]

Cliff,
  Ya wern't wrong!!!!!!!!!  Yuck! I am flat out filthy!!!! But the AC bay is flat out gutted. 
  Question tho, (Jerry too), there is an 1/8th in thick plate that runs from front to back in there. It's closer to the drivers side. Is that in any way structural? Looks pretty solid. Jerry mentioned it and I believe he said he left his. But I wouldn't mind taking that out.
  I'm also thinking about putting the batteries on the drivers side now and partition that off. Then put the inverter in the middle and the gen towards the door. Do any of you for see any issues with that?
  Thanx again!
          chaz

[FloridaCliff]

Chaz,

I'll bet your covered, but good!   

I did mine the way you are talking, except I put the inverter on the wall in next bay back.

I put it underneath the intermediate panel.

Two reasons, I knew I would be keeping that compartment vented with the genset and that means road dirt, water..etc

and I wanted some seperation from the batteries, plus its much easier to get too.

I also left that 1/8" plate, wasn't 100% sure and it wasn't in the way for my plans.

The wires I was talking about earlier were on the drivers side, someone may have previously snipped yours.

Cliff

[Chaz]

There was definitely "some sniping going on" previously!  I trimed them back even further since I knew they weren't used.

  I may also leave that 1/8th" panel and extend it up to create a seperate compartment for the batteries. The ventilation would be great there.

  Ok, so if you put the gen on the pass. side, did you have to move the aux. air tank? Jerry moved his perpendicular to the way it sits now. It gave him allot more height. I was wondering if I would need to do that. I'm sure it will depend on the gen. But, I can also move the tank straight up about 4", I think, since I removed the sheet metal that was over top of it.
 
  By the way, I actually had a sandbar of dirt in my shower when I got done washing up!! Man, was I dirty. A buddy came by about the time I was done working on the bus and was laughing at me and said I looked like a coal miner!!! 

  Thanx again!!
        Chaz

  p.s. My batteries come in tomorrow. 8 6v GC2H's It will be interesting to see how they fit!

[FloridaCliff]

Chaz,

Ok, so if you put the gen on the pass. side, did you have to move the aux. air tank?

Put mine on the Drivers side.

I have not yet moved my tank, but considering it when I move my start batteries.

Cliff

[Chaz]

Sorry Cliff. It sounded like you put the batteries on the drivers side. Is the gen there too?? Is there a rule of thumb about putting the gen on the drivers side??

  I'm thinking about putting (stacking) the bats there on the drivers side and using that 1/8" aluminum divider as the bottom of my partition wall. There would be great ventilation there and easy access to check them.
  I guess I need to measure some gens to see what I need to allow for one.

   Thanx Cliff.
     Chaz

[FloridaCliff]

Chaz,

My batterys are under the air tank.

I think there is a general rule of thumb to put the gen on the side away from where you typically would be sitting...away from the door....under the awning....to keep any noise away....


Cliff

[Chaz]

Makes sense............................................. d**n. 

  thanx bud.