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What Do I Do Now!

10/14/2011 01:13 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...


7-13-10
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




Interior

 



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

Upholstery
Drivers compartment ceiling

Closing in drivers compartment wiring..


AV in driver area


More upholstery for driver area


Interior

 

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



Interior


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
z

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


Interior
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


Ramp


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

6-26-10

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

6-11-10
Walls approaching the correct hieght and nearing the attachment the roof

6-10-10                                                                                                         Back to top of page



6-9-10

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.


6-6-10
All wring above driver area has now been released, Roof raised but is out of aline unitl we start connecteing 


6-5-10
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


5-31-10
Too Busy, No images
5-30-10
Too Busy, No images


5-29-10                                                                                                         Back to top of page

5-28-10 Bus arrived and unloaded


5-26-10
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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