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Rust

Yahoo Message Number: 98479
So, I am finding out that rust is the #1 enemy of coaches in my area of the country (Minnesota).  I suppose anywhere else that the apparently flavorless roads need seasoning - aka tons of salt - this would be a similar problem.

My $13,000 (and growing) repair bill for a new radiator (the coach's 4th since new) and charge air cooler (3rd since new) among other things that have rusted away is making me wonder what else to look for.  I have already done a lot of metal repairs to the chassis & body framework, welded in new steel where the steps had fallen off and the battery tray and under the generator and LP tank, and rebuilt wheel wells.  I'm a little concerned about the 1x2 tube steel under the water tank, but for now that appears to still be pretty intact.  I have the Cummins mechanic replacing whatever fuel lines and other metal engine components he finds that are deeply rusted.  The engine oil pan rusted through and was replaced a few years ago.  Next spring I will be replacing a bunch of the exterior lights where the bulb sockets have corroded away.

I have come to find out from visiting shops and talking to professional mechanics that while semi tractors and fire trucks, buses, etc. are built with stainless steel tubing and galvanized metals and other components to at least minimize rust & weather damage, for some reason even the high end luxury quarter-million-dollar motorcoaches - with the same engines and transmissions and drivelines as the commercial big rigs - are made with cold steel, no undercoating, and many not even with weather-tight electrical connections.  I guess motorcoach owners are not expected to drive in bad weather (which by the way is the exact answer my coach's previous owner got from Country Coach when he complained about the thing starting to rust apart when it was only maybe 4-5 years old, and he took immaculate care of it since it was new).  I have not and will not drive it in snow as long as I own it, and the number of times my coach has been driven in snow since it was new is less than 10, but I guess that's enough.
Yes my coach is 16 years old and has 120k miles, but I would have expected better durability from what in its day was a top of the line product.

So I ask my fellow Minnesota and northern states coach owners (both CC and other brands): Besides those mentioned above, what other areas of your coaches have fallen victim to rust?  Other than not driving in winter, what have you had success (or not) with repairing and preventing stuff from rusting away? While it is in the shop I would like to look for and fix whatever else I can think of.  Any advice or just sharing of war stories would be much appreciated.

Thanks,
Mark M

1998 Intrigue #10661

Re: Rust

Reply #1 –
Yahoo Message Number: 98480
Mark, we're in MN also, and ours is an 06 Inspire.  I don't think we've had any rust show up so far, but we have had 2 radiators, I think only one charge air cooler, PTO, one roof ac.  We have 100,400 miles I think, and have used it a lot as we use it for business.  We've traveled in only 1 or 2 snow storms, and fortunately can wait until the weather means clear roads before we get out.  We bought it new from Lazy Days in April of 06 and have gone to only one CC gathering, that being in 07 in GA where we had the opportunity  to meet up with those Howard folks who were happy to offer to have all three of our slides replaced as they were cracking.  That fall we drove out there with a route through AZ and CA for work, dropped the coach off, and they delivered it back to us in February  (really cold, so I'll add that snowy time for the coach to make it three times) with all three new slides, not the stuff inside, just the walls, etc.  It's all been good since then other than the radiator.  We use I-State in Inver Grove Heights for engine/radiator  type care, and have been happy with them.  It's really interesting to read all you wrote.  Very fine observations.  We agree that we expect these coaches to last a long time.

Mary Frederick
06 Inspire 51784

Re: Rust

Reply #2 –
Yahoo Message Number: 98493
My coach as no significant rust issues at all. It has been north only in the summer and spends the winters in Florida.
Archie Ritch

98 Intrigue #10657

Re: Rust

Reply #3 –
Yahoo Message Number: 98495
My previous coach, a 2002 Winnebago Journey, had a number of rust issues but none as severe as the OP describes with his Intrigue. The Journey's original owner lived in Illinois so I suspect that was a factor in the undercarriage rust I had.

Our Allure has no significant rust at all. The original owner lived in NC and it seems to be thoroughly under coated. However, inspect under its belly often and plan to be proactive in addressing any rust I see.

I guess it really does have a lot to do where the coach lives.

Gary

07 Allure 470

Re: Rust

Reply #4 –
Yahoo Message Number: 98496
Another reason for chassis rust is how it is stored. A building with an earth floor will cause Rusting due to the moisture in the ground  Classic car collectors are well aware of the problem Bob. 06 intrigue 12047