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Cabinet Work
Double Deckers
Eagle 20-1988-07
MCI 9 3316b
MCI 9 #3336
MCI 9 #5234
MCI 9 #6422
MCI 102-3305B
MCI 102-5236
MCI 102 5943
Prevost LeMirage
Scenicruiser 4501
Slide Out Units
Slide Out 5643
Stretched Van
Vinyl Graphics
What Do I Do Now!

10/29/2018 02:05 PM

Gillig Custom Suncruiser, Double Decker Construction Images.
Started 6-1-10, See bottom of page
Finished 7-13-10

Most recent Images and information on top...

Parked for pictures

Leaving Factory

In the factory about to leave

Drivers compartment
Behind seat, Dash, Over driver - circuit breaker compartment, behind and above driver seat 

7-12-10                                                                                                         Back to top of page


7-11-10                                                                                                          Back to top of page
wrap finished last night


7-10-10                                                                                                         Back to top of page



Generator cooling fans installed


7-9-10                                                                                                         Back to top of page
Prepping for new windshields,..

Installing mirror mounts

Lower Door/ramp in process

Rear wrap Installed

7-8-10                                                                                                         Back to top of page
Left and right rear corners finished

Rear and right side wrap started

Front end preparing for wrap

Installed chrome centers for wheels

Side door coming together

Installed hydraulics for door

Drivers compartment ceiling

Closing in drivers compartment wiring..

AV in driver area

More upholstery for driver area



7-7-10                                                                                                         Back to top of page

Second shift, midnight

New style telescopic Headlights in process

Upper door / awning installed

Welding more heavy Steel for bracing of Hydraulic ram for lower Ramp / door

More upholstery in driver compartment, behind driver seat 

Generator running under full load test and keeping it cooler inside bus


Upholstery caught up


Front Bracing going in behind upper front end,
Carpenters framing up on our framing 

All green lights now, ready to roll...

Left and right upper cowling in process

You can't tell in these images but the back doors are being prepped for wrap

7-6-10                                                                                                         Back to top of page
As requested, we are now closing forklift access openings and finishing front to receive vinyl wrap

Drivers test lights and main console controls are up and running

All Bus Chassis electrical circuits are now  responding..
Now we convert the red signals into green ones..  

"A few hours later and as of this publishing most all red lights are now green"

Welding up upper half of ramp door

Laying out upper half of ramp door


Wiring installed for ramp door operator controls

Hydraulic pump wired to operate ramp door

7-5-10                                                                                                         Back to top of page
Worked on front end and cap

7-4-10                                                                                                         Back to top of page
Front almost finished ...

Now would be a good time to consider not having upper windshields, could be a great area for more wrap ...

7-3-10                                                                                                         Back to top of page

Cleaning up and and resurfacing new front end to be smooth with proper contours (will take two days)

Because we are setting front cap back a little we must widen it

Interior Fiberglass reinforcement and re-attaching front upper cap

7-2-10                                                                                                         Back to top of page

Second Shift
Sizing upper windshield parts to fit new design..

Miscellaneous  body touch up

Installing last skylight

Making sure all rear doors hang properly

Drivers private A/C ducting installed

Earlier first shift

After fitting we will set back where the bottom will be flush


7-1-10                                                                                                         Back to top of page

Generator exhaust attached into main exhaust for bus


6-30-10                                                                                                         Back to top of page

Engine running smooth,

New front Brake shoes, drums and bearings.. left and right side

New rear Brake shoes, drums and bearings..


Door ramp opening

Skylights installed ..now finishing trim

First shift ..
laying up last layer for front end

Front driver compartment area

Main room


6-29-10                                                                                                         Back to top of page
Second shift
New brake parts and front end work, right side

All new seals for ramp came in

Skylights installed

More Warp work

Exhaust pipe trimmed, plus more door work,
Note handle on middle door along with gas springs attached

All new aluminum welded in sides to match existing wall around door casing for new rubber seals.

First Shift
Wrap started

Custom headlights in the works

Humidity delay has been solved and part  is coming together on time

Wrap  people making a start

Skylights being dry fitted, all fit perfectly...

New 2010 Style European mirrors arrived

Skylights installation,
Cleaning and painting frames black, prepping for later install



Tempered Glass made for these skylights wrapped in blue foam padding

Hinge for ramp going in, we finally now have the correct angles..

All materials ready to go ..

6-28-10                                                                                                         Back to top of page
More work on motor and back doors


First coat of finish gel coat

More work on mold

6-27-10                                                                                                         Back to top of page



Engine work


We do not normally show employees in  our images but today, Sunday, our fiberglass
crew came in straight through the week and they deserve a little hats off today.
..... Job, well done guys.....

Replacing Rear fiberglass corners


A/C installation


6-25-10                                                                                                         Back to top of page

Interior "B" court floor and wall

Mold getting thicker

Tires came in

More A/C Work


6-24-10                                                                                                         Back to top of page
New style Head lights

A/C compartment almost finished

Engine going in

Now we connect everything ...

More upholstery

Leveling flooring from past entrance ramp

6-23-10                                                                                                         Back to top of page

Structural Back wall of bus inside, carpenters kicking butt ...

Rear A/C ducts and wiring coming together

New return air to A/C unit
Right overhead supply to bus wiht more wiring through ducts to rear of A/C System

Exhaust Pipe was on roof, now protrudes into our A/C compartment..
We will direct it through side of bus when ready

Chassis treated and ready to be re-assembled

Mold Splash copy of front end still cooking
Front kicked , now waiting on sides to kick too

6-22-10                                                                                                         Back to top of page

Motor and transmission delivered

A/C unit in for dry fit


Some of the dash panels  upholstered

Splash copy Mold  of front end for upper deck laid up.
Now we wait to cure

6-21-10                                                                                                         Back to top of page
Large Commercial Air conditioning unit arrived  ..
Prepping to install

Prepping to start making mold to copy lower deck tonight

6-20-10                                                                                                         Back to top of page

Rear wiring junction box and sensors moved from inside to rear over Genset

Skylights started, cut out and bracing welded in place.


6-19-10                                                                                                         Back to top of page

Removing paint stripe down side of bus..

Rear, Generator, A/C compartment

Note Rear Wiring junction box moved from inside of coach to Generator compartment over Genset.

Double caulking with Sika-flex in expansion joints between panels
Note, front end in process of prepping to make new mold for second deck.

Front, driver compartment, dash

6-17-10                                                                                                         Back to top of page

Sample test for wrap,
Trim with sharp edges or rivets  .. Plain Rivets is recommended from wrap people

Inside started

Building Generator compartment, moved rear Bus breakers  into Genset compartment

6-16-10                                                                                                         Back to top of page
Left and right side walls fully skinned

Insulating inside wall panels with aluminum clad polyurethane foam board.

6-15-10                                                                                                          Back to top of page
Skinning almost finished

Skins built form Heavy duty 1/8" aluminum panels

Starting to cut floor out for the new entrance ramp mounting

6-14-10                                                                                                         Back to top of page
Main Structural walls complete, Now we smooth out welds for skinning and close up the ends.

Starting to design ramp for 10' door

Grinding down all welds to make flush, re-weld those that may need it.

Designing front area for new upper windshield and "A" pillars ...

Camera issues !!... ..These were all taken with the same light as above.

12KW Generator arrived

Now designing and building Generator compartment  area.

Aluminum skins waiting to go up

6-12-10                                                                                                         Back to top of page
Roof is now attached to walls,
Prepping for the new windshield "A" pillars.
Along with building in the rear generator and A/C compartment

Walls approaching the correct hieght and nearing the attachment the roof

6-10-10                                                                                                         Back to top of page


6-8-10                                                                                                         Back to top of page

Radiator, Turbo and transmission cooler  sent out to be reconditioned

6-7-10                                                                                                         Back to top of page
Today and over the week end

Monday am Picked up engine

Wheels ready to be sent out to  be reconditioned and replace tires


Bumpers ready to send to our rebuild shop in MD

Brake drums off, Prepping to replace and recondition

Inside de-skinned except for aluminum panels that assist in strength in side walls.
Will remove later when we remove flooring.

All wring above driver area has now been released, Roof raised but is out of aline unitl we start connecteing 

Engine out

6-3-10                                                                                                         Back to top of page

Roof release has been giving us a fit ..
We normally can have the roof released within 3 days ..
This one has become a challenge but we will still make the deadline.

Area above driver is where all the air tanks and  main wiring trunks going from front to rear junction panels

All the roof is loose  except for the front end ..where the utility bridge is ..

     Heavy  2"x 10"  Aluminum extrusions main beams in all walls

Chassis  is in excellent condition.

Engine /transmission will be picked up Monday


6-2-10                                                                                                         Back to top of page
Many things were attacked today but not all can be caught on camera.
The biggest accomplishment along with more releasing of the roof from walls was removing this
large Evaporator/ Condenser/ Heater core

This will be the new Generator compartment

6-1-10                                                                                                         Back to top of page
Disassemble Bus...                                                                                                       

Sample Cut to confirm construction material,
Solid extruded aluminum window post

Blocked up                                                                                                         Back to top of page

Too Busy, No images
Too Busy, No images

5-29-10                                                                                                         Back to top of page

5-28-10 Bus arrived and unloaded

Driver called, almost through Texas and said will be here late Thursday night 5-27-10
We will be here to unload Friday, Dawn ..will start working on bus within an hour

5-24-10                                                                                                         Back to top of page
Bus loaded on Dorp deck carrier, left Riverside California 5:30 pm and on the way...

(Date on images are incorrect)

5-20-10                                                                                                                    Back to top of page


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