Jump to content
Sign in to follow this  
bikeryder

Monaco Cayman Engine Air Intake Grille Problem

Recommended Posts

I’ve recently discovered a major design flaw with my 2003 Monaco Cayman’s diesel engine air intake grille. What has been happening is water migrates through this poorly designed grille and it has warped my bedroom floor behind the closet. I’ll pull up the wooden floor and replace it with marine grade plywood, but first I’ll need to address replacing this worthless factory installed air intake grille [see pics]. BTW, the cracks you’ll notice in the pics were recently created when I took off this grille to inspect behind it [grille is old and brittle]. These cracks have nothing whatsoever to do with water migrating into the interior of my Cayman.

I’m thinking about having a custom made 1/16” [0.0625] thick aluminum grill fabricated and welded. The overall dimensions “horizontal outside of flange lip” to “vertical outside of flange lip” are: 10 ½” H x 22” V.

Has anyone had a similar experience? Additionally, anyone out there know of someone with experience that actually custom manufactures such grilles?

Any and all suggestions are greatly appreciated.

Thanks in advance...

Eddie

1FAEAB42-8229-4662-A60D-F6DEBDC1944D.jpeg

CAF3F6C1-CC08-4BDC-B167-36597E94B244.jpeg

CD9430A7-0EE0-4537-BC7B-F04A5F0B80E6.jpeg

3601C48A-4691-4612-B1EB-907F7F3DBB63.jpeg

A1E22C7E-7487-4AD7-A7D6-701257F543B1.jpeg

ED5897B1-BBCC-4B49-B6AA-8A85922DB1E5.jpeg

810822A1-8D66-4235-BA31-0FC58540D390.jpeg

BCF2E5AC-89FD-4CA8-88A2-B30F51C2F1F6.jpeg

A8E496C0-0EAF-448A-90E3-03669652F03A.jpeg

FFF6045B-4DA4-4B55-AB85-5B75B9E55A9F.jpeg

Share this post


Link to post
Share on other sites

Is that one fiberglass or plastic? If fiberglass, you can purchase glasscloth and two part resin at most auto parts, boat repair, and Walmart stores. As handy as you are, you can repair that one and make a good looking repair of it. Most good sheetmetal shops should be able to make a good replacement using the old one as a pattern, that is of course they are willing to do so. I have such a shop that I do business with here, they don't do shipping, but if you are interested, PM me and I will try my luck for you. Are the louvers fixed position, or do they open and close by air or hydraulic? You could easily make a new one out of Fiberglass, just pour a plaster reverse mold using the old one, then refabricate the new one out of fiberglass.

Share this post


Link to post
Share on other sites

Good morning kaypsmith,

The brown grille is made of aluminum, and it’s housing receptacle is made of plastic. I’ll need a complete redesign. If you’ll notice the grille itself, does not have much of a slope to allow water run off. Additionally the grille louvres are much too short to do any good keeping water out. I’ve attached a very simplified sketch of something that might work better in preventing water migrating into interior of my bedroom area.

So, bottom line is an exact replacement will not resolve my issue.

Thanks so much for you input...

 

317BA27C-76CC-4B00-A5CA-CA51B3EEDE83.jpeg

Share this post


Link to post
Share on other sites

Eddie, thanks for the update, I did send a PM back and will be awaiting a reply. I do computer work these days, and I do the upkeep of the sheetmetal shop. I'm sure that something can be made to happen. The drawing is very good and .125 aluminum will outlast both of us. Of course, I do need exact opening dimensions, and maximum depth both top and bottom. Oh yes the standard aluminum is brushed, I am not able to get anodized unless it is diamond plate, which will not look very appropriate for your application. The brush finish can be primed and painted though.

Share this post


Link to post
Share on other sites

Kaypsmith,

The fact that you work with someone you trust, as well as having a familiar understanding of how the various components on a motorhome function, I’m feeling pretty confident your suggestion of using the metalshop close to you just might work out. I’ll PM you later today. As always, thank you kindly...

Eddie

Share this post


Link to post
Share on other sites

Eddie, good luck to you.  Please post a finished photo!  Good, clean drawing!  Looks (in your photo) like the factory over tightened the upper left bolt/screw and caused a stress fracture in the plastic!  That's beyond a poor design.

Share this post


Link to post
Share on other sites

Good evening Manholt,

Yes, this plastic Air Intake box is awful. What a mess it has created. Once the stainless steel replacement air intake box and grille is fabricated and installed, I’ll most certainly post updated photos. After that, I’ll begin the drudgery of having to pull ruined carpet and flooring. Not to mention disassembling my entire rear closet with drawers, wardrobe and sliding mirrored doors. I’m not looking forward to this at all, but it must be done. 

Thanks very much for your encouragement.

Eddie

Share this post


Link to post
Share on other sites

Eddie.

Just a thought as for the air intake box is concerned.  take it to a 3D Plasma Shop,  we got them, so I would be surprised if So. Cal., did not.

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now
Sign in to follow this  

×