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Author Topic: Race Deck Projects  (Read 5881 times)
Nick Badame Refrig/ACC
1989, MCI 102C3, 8V92T, HT740, 06' conversion FMCA# F-27317-S "Wife- 1969 Italian/German Style"
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« on: January 20, 2010, 12:50:18 PM »

Hi Guy's,

Just thought you guy's would like to see my latest projects.

This is the first deck of 3 to be built and most likly this is the hardest since it has roof airs in the way..

The next two have basement systems.. [ 01' H3-45, & 99' XL are next]

This coach belongs to Star Coach Race Tours, it's the same 03' H3-45 I had here in September for

a complete Webasto install. This deck's sub structure is constructed out of PT 2"x 4" with custom

steel brackets attached to the crossmembers. It will have a composit [brown] decking surface and

1"x 42"H, 2 tear aluminum railing system. All the railing hardware is from KEE KLAMP.

Decks are 24'x7' and custom grated covers will be constructed over these a/c's and used as tables.

http://www.starcoachracetours.com/Home.html

Nick-
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« Reply #1 on: January 20, 2010, 01:21:50 PM »

That's very interesting...I'm planning a roof deck for mine, although only for about a third of the length of the roof. Mine will be made of steel with a Tek-Dek type surface, and I'm making the outer edges fold into the centre so no part of the deck can be seen from the ground when it's not being used. It'll also have a fold-up bimini-type top over it, and possibly removable sides as well - I have an idea that in warm weather it could almost be used as an extra room for eating, reading or socialising.

With the ones you're doing, how will people get up there - ie., an external ladder or roof hatch etc? Also, how will the side railings be attached to the deck? The forces on the attachments at the base of the railings can be enormous when someone is leaning against them.

Jeremy
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« Reply #2 on: January 20, 2010, 03:29:25 PM »

That is a very different way of building a roof deck.  I have seen most made of aluminum or stainless.

Isn't it awful heavy with PT wood?  PT is usually almost dripping wet and heavy when new.  I've always wanted a roof deck and this could be a good way to make one for less money than a metal one.
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« Reply #3 on: January 20, 2010, 04:03:23 PM »

that is an AWESOME project. Please post updated pictures for  us :-)
I had something like this in my imagination, but yours is better.

Are you worried about hurting the  roof a/c's efficiency by bocking its ventilation around the edges? I'm sure you thought of that though.
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Nick Badame Refrig/ACC
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« Reply #4 on: January 20, 2010, 05:38:40 PM »

Hi Guy's,

What you are seeing in the second picture is the main PT supports that are lined up with the 32" on center

sub steel supports that are under the the bus roof. Tomorrow, [day 3] we will be adding 16" on center PT

framing that will be supported off the 32" on center structure and not in contact with the bus roof. Also, you

may notice that the outer 2x4's will be 2 1/2" in from the sides of the deck. This is for extra support for the

railing structure's base mounts to anchor to. The very most outter sides of the deck will be skirted with brown

decking material for a finished look. Then the composit decking will be the last step. The finished height of the

deck will be 4" below the top of the a/c's for clearance purposes. The dometic penguins vent at the lowest

part of the upper unit which has access to the under clearance of the structure.

Keep tuned in, I'll post more pics as it comes together.

Nick-

PS, below are examples of the Kee Klamp railing hardware.
« Last Edit: January 20, 2010, 05:48:35 PM by Nick Badame Refrig. Co. » Logged

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« Reply #5 on: January 20, 2010, 06:57:44 PM »

Pretty cool Nick! Having plans in the future for some Nascar races I see the need to do something like that. I'll be watching your progress and hope you keep showing us pics. When you get done give us a "hindsight is 20/20" commentary to help us out.
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« Reply #6 on: January 21, 2010, 02:42:58 AM »


Have you considered the vinyl decking material?  That dark composite stuff can get mighty toasty up there.  Of course the bright white vinyl can help burn the bottom side of the beer belly too Cheesy.   And the Vinyl is pretty light.



Pretty kool project!!!
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« Reply #7 on: January 21, 2010, 09:00:44 AM »

Nick I have two questions..   

Can we see how your Webasto install looks in the Prevost.   Snag some pictures for us..

2nd..   Are you using and grommet or sealant between the aluminum roof, and you brackets that you are screwing into the roof supports.   What I am getting at is>> with people walking on the roof, the load gets placed on the brackets (there is motion and movement).   In construction terms are you hot mopping around the brackets prior to getting the decking installed?

I like many others are looking on with great interest..   Good luck
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« Reply #8 on: January 21, 2010, 10:50:02 AM »

Hi Guy's,

This deck's sub structure is constructed out of PT 2"x 4" with custom

steel brackets attached to the crossmembers. It will have a composit [brown] decking surface and

1"x 42"H, 2 tear aluminum railing system. All the railing hardware is from KEE KLAMP.

Decks are 24'x7' and custom grated covers will be constructed over these a/c's and used as tables.

I thought about doing it that way, then discared the idea.  You are getting on the wrong side of the strength-to-weight ratio,  compared to using a steel or aluminum substructure, plus adding a maintenanca issue (how will they paint the wood every year?) AND adding several square feet of built-in headwind.

When I get around to doing mine, I will buld a steel or aluminum frame, attached to the tops of the pillars.  Using 1-1/2" x 3/4 channel, I will have solidity, good weight transmission across the entire frame and into the entire coach (retaining the monocoque stress distribution) and be in about the same weight range (if not lighter) than the wood and plastic deck.  It will also mean no weight on the roof.

My rails will be hinged, with the side rails like those on a hospital bed, carrying the front and rear rails with them, so setup will be simple -- park, climb up the front hatch and lift the front half into position and lock, then go to the rear and do the same there.
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« Reply #9 on: January 21, 2010, 11:30:58 AM »

Nick- I know you're the A/C expert, but the venting of the Penguins with it's squirrel cage blower requires around 6 inches of clearance space on that side of the A/C.  I don't see that kind of clearance.  And if it blows under the deck, it will get super heated to the point that the A/C's won't breath (but then you know that).  It might be advantageous to move that 2x4 about 6 inches away from the exhaust of the A/C's.  Good Luck, TomC
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« Reply #10 on: January 21, 2010, 01:15:47 PM »

Why would PT wood need to be painted?
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Nick Badame Refrig/ACC
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« Reply #11 on: January 21, 2010, 02:05:13 PM »

Hi Tom,

The customer has been informed about the clearances months ago... We will see how that pans out this summer.

Hi Zero,
I will post the Webasto pic for you.

I don't have much time to write now but here is another pic.

Nick-
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Nick Badame Refrig/ACC
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« Reply #12 on: January 21, 2010, 07:18:35 PM »

Hi Zero,

My custom steel brackets are sealed to the roof with Di Core which is a RV roof sealant.

The steel brackets are connected to the bus crossmembers with 1/4" thread cut machine screws. [45 mounts]

Tomorrow the composit decking will be pilot drilled and screwed down and hopefully Saturday I can start the railing system.

Nick-
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« Reply #13 on: January 21, 2010, 07:40:10 PM »

Are you going to have a toe kick?
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« Reply #14 on: January 21, 2010, 08:41:17 PM »

Is a toe kick something to assist you when you get too close to the edge and find it as an incentive to fly?

My question is 'Is there some kind of protective railing or a chain that can be placed around the edges of this deck to prevent such a mishap?' What do you plan for this? I am curious.

Keith
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« Reply #15 on: January 22, 2010, 12:29:23 AM »

Why would PT wood need to be painted?

Pressure treatment makes the wood more dense, thus restricting water absorption, but not preventing it.  Eventually the wood will begin to deteriorate.
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« Reply #16 on: January 22, 2010, 04:25:01 AM »

My main concern would be the weight, but I'm sure Nick has it figured out!

Paul
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Nick Badame Refrig/ACC
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« Reply #17 on: January 22, 2010, 04:45:45 PM »

Day 4, Composit decking is complete!

Tomorrow, the railings will be installed.

Here are some more pics
Nick-
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Nick Badame Refrig/ACC
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« Reply #18 on: January 23, 2010, 03:04:24 PM »

Day 5, Complete.


Nick-
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« Reply #19 on: January 23, 2010, 04:06:49 PM »

awesome Nick that looks  great.  I don't  think it would look quite  as good on the curved roof of an MCI.  Is there going to be a permanent ladder on the bus? How about an elevator?  How  much does that composite stuff weigh (compared to treated  lumber?)
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« Reply #20 on: January 24, 2010, 05:51:45 AM »

Looks good Nick!
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« Reply #21 on: January 24, 2010, 05:56:31 AM »

Don't forget to reweigh the coach and adjust the tire pressures as may be necessary!
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« Reply #22 on: January 24, 2010, 09:58:35 AM »

Looks great!  But with over 400lbs of A/C and now another, what 500lbs of wood-have you tried driving to see if it feels top heavy?

I still maintain the A/C's should have better exhausting for the condenser.  Maybe just cut a hole in the 2x4 support next to the squirrel cage exhaust so the hot air can exit under the deck-and then also cut another hole in the 2x4 on the outside edge for venting?  But-the hot summer months will tell.  Good Luck, TomC
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« Reply #23 on: January 24, 2010, 05:03:01 PM »

Thanks Guy's! The customer is super happy!!

Tom,

I just got back from delivering the coach to Baltimore. I didn't notice and weight difference or power loss at all...

Funny, I did cut 1-12" holes in the 2x4's on both sides of each unit as you stated!!

Philip,

A fold up ladder will be used until the coach gets back from Daytona 500. I will be designing/constructing an aluminum

stair cases that will break down and be stored in the bays.

Next Sunday, I pick up the second H3-45 in Nashville.

Nick-

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« Reply #24 on: January 24, 2010, 05:50:48 PM »


Looks pretty cool Nick, when we going to the race Smiley     

One thought is that you may want to put something on the lead of the deck to divert the wind off the front edges when it is doing 90mph down the highway.   Don't want deck or the deck boards lifting off.  I'm not sure if you used stationary deck building methods or how they will hold up in high winds.

Interesting project.
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« Reply #25 on: January 24, 2010, 05:56:47 PM »

Looks great Nick, Keep up the good work. Jason
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« Reply #26 on: January 24, 2010, 08:23:05 PM »

Quote from: Nick Badame Refrig. Co. l
Thanks Guy's! The customer is super happy!!
Tom,
I just got back from delivering the coach to Baltimore. I didn't notice and weight difference or power loss at all...
Funny, I did cut 1-12" holes in the 2x4's on both sides of each unit as you stated!!
Philip,
A fold up ladder will be used until the coach gets back from Daytona 500. I will be designing/constructing an aluminum
stair cases that will break down and be stored in the bays.
Next Sunday, I pick up the second H3-45 in Nashville.
Nick-

Nick,
When will you be getting to Nashville?
I'll be in Nashville all day Sat. 01/30/10 with an indoor track team.
Would be great to meet up with you. I'll buy lunch, if you can make it.
Grin  BK  Grin
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Nick Badame Refrig/ACC
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« Reply #27 on: January 25, 2010, 07:12:43 AM »

Hi BK,

I will know for sure by Thursday but, I am schedguled to fly out on Sunday night.

I will call you if it's any earlier.

Nick-
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« Reply #28 on: January 25, 2010, 01:01:55 PM »

Nick;

It would be interesting how close the H3 is to mine in the '03 assy.

I noticed that there were a few roof patches?   How are they holding up.   

Can you start a thread about your Webasto installs.   We know that you refurbish these units.   I think that a few of us would be interested in the finer details of the install..

I am looking for the side bracket that holds the fuel filter and circ pump.   Do you have a extra on for sale?

I have a new U8202 pump that I want to mount on the side on the factory bracket.

Again THANKS for posting this thread..
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Nick Badame Refrig/ACC
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« Reply #29 on: March 02, 2010, 07:39:13 PM »

Headded to Atlanta on Wednesday.

First stop, Baltimore to hop abord the 03 H345 and run to TN to pick up another H345. Then running to

Atlanta Motor Speedway to set up all 3 Prevo's in the infield for race weekend. Friday morning I will hop

on a flight to west palm beach to pick up the company's 07'Phayton S&S.. and drive it back to Atlanta to

join the fleet in the infield. Then Hopefully I can relax and enjoy the races before we will pack up Sunday night

and head Back to Baltimore with all the coaches except the newest Prevo that I will take back to my shop

for Shower, tanks, and plumbing install since this coach is a 12 bunk sleeper with only a toilet in it.

Should be fun!
Nick-

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http://www.starcoachracetours.com/star_coach_race_tours_fleet.html
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« Reply #30 on: April 13, 2010, 08:10:52 PM »

Hi Guy's,

I finished the second Prevost H3-45 Race Deck and I'm sorry for not posting progress updates

because there seems to never be enough time in the day. Sad

Anyway, The first deck had stood up to 25 humans on it and 5 events allready. [even though I stated 12 max]

The second deck is much bigger [7'x 29'] with no roof warts in the way.. So, it's ready for Talladega now.

Here's some pics..  Also see my company's Facebook page for step by step progress below in my signature.

Nick-
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« Reply #31 on: April 14, 2010, 05:27:34 AM »

That really looks nice Nick!!!
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« Reply #32 on: April 16, 2010, 12:25:18 PM »

Hey, do you have any pictures of your brackets and how they fastened into the roof and how you sealed them?  We are actually in the process of potentially doing this to a friends bus, but are going to use a pontoon deck.  All aluminum frame, w/ marine grade plywood and vinyl covering.  going to cut the aluminum rails off and fab up some higher "non pontoon looking rails".  The aluminium framing weighs a little over 200 lbs for a 24' long and 8' wide platform.  i was going to fab up 8 custom square feet i could bolt to the bottom of the toon deck before setting it on top the bus, then I was going to bolt her through the cross members.  I didn't think i could rely on screws.  Last think i want was for it to catch wind and fly off....or worse, rip part of the bus roof off when it went.

thanks,

Greg
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« Reply #33 on: August 29, 2010, 04:08:07 PM »

Just completed & Delivered the 3rd Race Deck for Star Coach Race Tours.

Their company is growing real fast...  They now own 7 of the 11 coaches in

their fleet..

This Prevost is a 2002 entertainer. [Florida Coach unit]

Enjoy
Nick
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« Reply #34 on: August 29, 2010, 05:10:27 PM »

Good for you Nick,

I just returned from Dover Downs for a night and taking a morning walk around the track (outside) I was thinking of your rooftop conversions.

Hope you are well, and had a profitable summer.

Gary
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