1991 350LE the "Zephyr"

[cmadmaxman]

Well its been a fast 4 months of working on our new project. The 1991 350 LE.
We contacted the past owners of the 350LE, and we have kept the name they gave her for over 20 years of ownership.
Marilyn and her late husband Garmann were the second owners of her, and we wanted to keep the name in honor of their many years of love and care for the Zephyr.
A couple of owners after them, but not many miles after there ownership.


On the morning of July 18th, we (my Son and Me) changed out the 13 year old tires to the new Goodyear's at the owners home. Headed out of NC over the Smokies at night and got her here the next morning.


We need to get the Zephyr to the rest of the states that Marilyn and Garmann did not get to. Marilyn said they got Georgia and Florida before Garmann passed.


I will post many more photos of what we encountered during the last 4 months.

Thanks to Peter so much for help with our new project.

[cmadmaxman]

First on the list was to fix the steps. Alltho they had replace many years ago to the Kwikee steps, the motor was toast and the wiring had been so jacked up, a new motor and control was in order.
Kwikee 379160 Gear Box control.


Had to do a little straighten of the linkage, and installed the new gear box, motor and control.
Wiring went ok and now have the step working as good as new.

[cmadmaxman]

The next big problem we found out, was major rot in the rear floor under the fresh water tank and trunk. We knew we had some issues, but not this bad!
Due to years of the vent pipe leaking and other leaks in the water supply and the leaking from other leaks in the windows and such, made for a mess!









The main walking area was ok, but beyond that on the rear and left side, not so good. Also with AS putting down padding, carpet then a plastic vapor sheet on top of all that, keeps all that moisture trapped to keep the rot working!









So replaced 3/4 th of the floor in the rear.

[cmadmaxman]

Here is what he frame work looks like under the floor!
And yes that is a pile of the sheet metal we took out.









New floor going in!

[cmadmaxman]

Here is where some of the problem was with water intrusion. Thanks AS!







Here is my fix for the screen on the vents. I used JB weld to put in screen wire in the opening so no trash gets into the opening. This also lets the rubber seal, can we say, seal around the pipe like it should.



Sealing up every thing that I can think of might let any water in!






I also replaced the seal on the boot, as well replaced the ball mounts for the shocks. The seal now can seal against the door. Removed the steel mounts and bolted new ones on the inside of the frame so the seal seals all-around.

[cmadmaxman]

New flooring going down. LVT vinyl.

Will be doing the step well soon with oak, gone will be the plastic stuff!

[cmadmaxman]

All new fresh water plumbing with PEX and all brass fittings!



Here is what the head looks like with all the carpet gone, and LVT in place.



Also replaced the dump valves with the other brand!

[dadstoy]

At first I was wondering if you were doing all this work in one day! Ha Ha. That is a lot of awesome work you are doing! Your cold/hot water plumbing looks so great compared to the factory work. I've been following your progress and enjoy seeing your work!

[Magnet18]

Fantastic progress, looking great!

[bkahler]

Airstreams may look nice on the outside but I've always felt they really don't know how to engineer anything.

Awesome work you're doing

[cmadmaxman]

Thanks y everyone.
As I have worked on 2 of these coaches, yes I wonder about AS manufacturing process! But, they have good bones as one would say. Not to many SOB units out there that have been around as long, and also the potential if taken care, live as long as our coaches.

That being said, here is another current fix on the Ramco mirrors.
This model mirror from Ramco has to move the whole unit to adjust the convex mirror. When I could not move em, I found the rusted in set screws and broken plastic inserts to be the problem.



It took some time, and many applications of PB blaster to get the set screws out, take your time! When removing, take the bottom cover off the mirror arm. Watch the wire going into the mirror, you will need go get as much as possible to get the ball of the mount clear for removal of old plastic pieces and to install the new inserts.



I was able to order the up graded inserts made from aluminum direct from Ramco. New SS 3/8-16 X 3/8 from Bolt Depot, and the mirrors now move like they should for adjustment of the convex mirrors.

Attachment 383817

[cmadmaxman]

While I was replacing the brakes on the Zephyr, I made a couple of changes up front with the metal guard with the access hole for the master cylinder.
I cut the small part of the guard above the opening to view the reservoir so I could get it out of the way, and to get to everything it hides. This shows you the hydraulic valves to control the parking brake release powered by the power steering pump.



Master cylinder was in need of replacement!



Here is the new MC installed, as well, a new high pressure hose.



While I was at it, I installed a oil cooler for the powers steering system, due to the pump is doing triple duty!



Cleaned up the metal guard and completely cut out the small part of it above the opening. This makes it much easier to see the reservoir, and also lets you completely remove it if you need to get back in.

[PeterH-350LE]

Originally Posted by dadstoy

At first I was wondering if you were doing all this work in one day! Ha Ha. That is a lot of awesome work you are doing! Your cold/hot water plumbing looks so great compared to the factory work. I've been following your progress and enjoy seeing your work!

Dean, Just look at his forum handle "madmax", I tell you that guy tears it down and puts it back together in no time. He has been doing an awesome job and we have been able to compare notes on some issues that just don't make sense. Looks like the Zephyr will be making a pit stop in Austin on the way to Arizona. Looking forward to seeing it in person.

[cmadmaxman]

Thanks Peter. I think it's more "mad" at times!
Old man don't get down and up like he use to.
Has helped working on the 310 for over 14 years!

Here is a little trim job on the step well. Not perfect, but much better than the old plastic junk!

Before and after:

[bobmiller1]

Yeah, that plastic insert was garbage when it was new......terrible idea, you did a great job, it’s on my short list of modifications to complete. Regards, Bob

[cmadmaxman]

Thanks Bob.

It takes a little time to do, but well worth the final results. I Drilled and taped 10-24, and used SS bolts, so all parts can be removed if the steps need removed.

Here is a night shot

[cmadmaxman]

Hey Peter, maybe I need to change my photo to this

[cmadmaxman]

502 Chev big-blocks topped with fully functional 8/71 blowers for an estimated 1200hp.

[PeterH-350LE]

Originally Posted by cmadmaxman

502 Chev big-blocks topped with fully functional 8/71 blowers for an estimated 1200hp.

Attachment 384584

Oh no, now he lost his mind Does that come with 2 4l80E's?

[cmadmaxman]

They started with a TH400, but toasted it, wound up with a truck Allison!