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07/13/2010 06:29 PM
Welcome to our latest
Gillig
Suncruiser, Double Decker Construction Images.
Production # 5329,
Started 6-1-10,
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Finished 7-13-10
Most recent Images and information on top...
7-13-10
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
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7-11-10
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wrap finished last night
   
7-10-10
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Interior
  
Generator cooling fans installed
7-9-10
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Prepping for new windshields,..
   
  
Installing mirror mounts
  
Lower Door/ramp in process
  
Rear wrap Installed
 
 
7-8-10
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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
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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
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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
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Worked on front end and cap
   
7-4-10
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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
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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
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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
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Generator exhaust attached into main exhaust for bus
 
6-30-10
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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
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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
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More work on motor and back doors
 
Ramp
 
First coat of finish gel coat
  
More work on mold
 
6-27-10
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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
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Interior "B" court floor and wall
  
Mold getting thicker
   
Tires came in
More A/C Work
 
6-24-10
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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
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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
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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
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Large Commercial Air conditioning unit arrived ..
Prepping to install
   
Prepping to start making mold to copy lower deck tonight
6-20-10
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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
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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
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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
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Left and right side walls fully skinned
   
Insulating inside wall panels with aluminum clad polyurethane
foam board.
   
6-15-10
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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
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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
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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
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6-9-10
  
6-8-10
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Radiator, Turbo and transmission cooler sent out to be reconditioned
6-7-10
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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
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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
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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
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Disassemble Bus...
   
  
  
Sample Cut to confirm construction material,
Solid extruded aluminum window post
   
Blocked up
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5-31-10
Too Busy, No images
5-30-10
Too Busy, No images
5-29-10
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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
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Bus loaded on Dorp deck carrier, left Riverside California 5:30 pm and on the
way...
  
(Date on images are incorrect)
5-20-10
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