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Old 06-28-2015, 10:41 PM   #1
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1991 30' Airstream 30
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GLAMP '94 Classic Pusher

A couple of months ago I flew out to Phoenix and bought a 1994 Classic Diesel Pusher. I had always been a big fan of them, and it was the only possible trade up from a 300LE. When I got a look at it, I almost got back on the plane and flew home, but having worked on several of these Motorhomes over the years, I figured I could bring it back to life. The motor was toast- the PO had overheated it due to a hole worn in the radiator hose, then parked it after having a shop take the head off to see what the damage was. The interior is in fair shape, and the exterior had a bad case of sunburn from life in Arizona, and a big dent on the top rear. It was the simplicity of the chassis and access to everything that really sold me on it, also, low miles and zero rust.

I had Kent's Diesel Works pick it up with his spotless tow rig and bring it to his shop, then I flew home. Kent rebuilt the motor...new everything top and bottom as well as radiator recore and CAC repair, KDP kit, check the AC, new front brake pads batteries, etc. Its a long list and was not cheap.

I flew back out and picked it up and drove it back to the Bay Area. Drove great, and amazed with the mileage! Love the engine brake and 6 speed Allison on the Grapevine.

Projects since then:
Repaired the dent on the rear, two new top panels and one corner. Was not that hard really, nothing to be scared of for a DIY project.
Tore out the carpet, and new flooring underway, real teak and holly this time.
New curtains and blinds from Arlene Fowler, look great!
Got some Ebay parts for the cruise control and replaced the actuator in the back, works now!
2 new 6 volt batteries up front.
2 new hoses for the HWL leveling system...still need to do some troubleshooting on that as one of the legs won't stay down.
Tore out all the TV's and the backup monitor that was loose. There is a bit if "aftermarket" wiring, but in general it looks good.
Ran a hose from he crankcase breather to the back of the rig behind the radiator- thanks Kota!
Stole the side awning off the 300...sorry next owner.Click image for larger version

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Old 06-28-2015, 10:50 PM   #2
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1991 30' Airstream 30
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GLAMP 94 Classic Pusher

Ok, the to do list:

Finish the floor...lots of work there.
Strip off he clearcoat and new decals.
Banks kit.
New bathroom counter and sink.
New sound insulation on top of doghouse.
New backup camera system.
Sound system, where to put speaker dilemma again!
Fire suppression system (may start a thread on this topic).
Clean AC units.
More I'm sure.

Learn a lot about diesel motors!

Go camping!
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Old 06-28-2015, 10:52 PM   #3
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1991 30' Airstream 30
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GLAMP 94 Classic Pusher

And on the camping note, on July 24 we leave for a two week road trip to Jasper, down to Yellowstone, back west and down 395, over the hill and home...should be fun...hope it's reliable.
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Old 06-28-2015, 10:59 PM   #4
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One concern I need to look into...I had it out last week for a drive to he DMV, and had the AC on. With the TV and backup monitor out, I have plenty of access to the dash wiring, so I did what anyone would do when I got back, and felt as many of the wires as I could reach to check for excess heat. The wiring going to the climate control was very hot, especially a blue wire. The crimp terminal looks like it's in good shape, so I need to do some digging around, check wiring diagrams, ground wires etc. I already cleaned up all the ground wires I could see...
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Old 06-28-2015, 11:05 PM   #5
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Anyone need a 1991 300LE? Think is tricked out and runs perfect. I want to do a couple small cosmetic projects on it, but I may post it on Craigslist as is to see if there is anyone who wants it for Burning Man.Click image for larger version

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Old 06-29-2015, 10:09 AM   #6
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GLAMP 94 Classic Pusher

Lookin good! How about a bit more info on the panel replacement. Source and cost would be handy. Doghouse 2 has a dent on one of the upper rear panels and some hail damage. The lower rear corner panels have been abused and should be replaced. I'm also having a hard time finding the plastic banana wrap panels.

Looking forward to following your progress.
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Old 06-29-2015, 05:48 PM   #7
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Wow! That sounds like the ultimate classic MH. Keep us posted.
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Old 06-29-2015, 07:54 PM   #8
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Hey Kota, sorry I did not take photos of the repair. I got the panels from my local dealer Bay Are Airstream at a discount...it's the shipping that kills you on these. Got rivets and shaver from ODM rental program, as well as a roll of mastic. You need a rivet gun, offset tin snips, cordless drill and drills.
You drill out the rivets (a spring loaded center punch helps to get the drill on center), remove bent panel and stomp it out...use it as a template for the new panel including any holes for wiring lights or air intake. Take your time fitting it and measuring...you know the old saying. I did a lot of test fitting but the new panels have the holes drilled out where needed. Add mastic to new panel and lightly coat with baby powder so it won't stick till you have it riveted in place. I drilled a couple holes then added rivets as I went. Do corners panels first, center last. Snip rivet heads and shave, and seal with caulking. I added new LED lights. Three panels took the weekend. Drink beer and admire.
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Old 06-29-2015, 07:55 PM   #9
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BTW, I don't think you can find the lower plastic pieces, but they should be simple to repair and paint...mine need some love as well.
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Old 07-01-2015, 01:22 AM   #10
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Originally Posted by SebasSF View Post
BTW, I don't think you can find the lower plastic pieces, but they should be simple to repair and paint...mine need some love as well.

About 3 years ago I called AS and was given part numbers, prices, and availability. Nobody can find them today.
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Old 07-07-2015, 11:03 PM   #11
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While looking for a shut off valve for the fridge ice maker I happened to find a flexible propane hose... a shake and was rewarded by a nice hiss sound. The rubber hose had been rubbing on the mounting bracket for the regulator, it was wrapped around behind it and the edge had cut into it. Not a hard fix.Click image for larger version

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Old 07-08-2015, 07:01 AM   #12
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Good catch! There are things that should be thoroughly inspected initially and annually. The propane system being the most important. The fuel system next but not as critical on a diesel. Then electrical.

Make it safe and reliable then purdy!
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Old 07-12-2015, 11:11 PM   #13
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New soundproofing for the doghouse/bed. Kind of a pain to get installed with contact cement.Click image for larger version

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Old 07-12-2015, 11:17 PM   #14
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And...gotta have tunes. I will be running Apple AirPlay off a modified for DC Apple airport express with no Click image for larger version

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Will need to rebuild the dash...
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