Interesting 2 days
Posted: Wed Jul 03, 2019 3:17 am
I was supposed to be off from BMW Mon through Thurs, but we got a call from the Mercedes Vans plant in Charleston wanting a custom job done, so I volunteered. I spent the last 2 days on this job.
We had to do some custom work on a 2019 Sprinter Winnebago camper. We had to remove the genny, waste water tanks, siding panels and other stuff. Then we installed these anti rollover outriggers so they can test this thing for what speed it will roll over cornering. There is another set that goes on the front that basically requires removing the bumper and bolting it on with 8 bolts that they will install themselves. Needless to say, things didnt go as planned. These rear outriggers we installed were custom built to the tune of $12,000, and I dont know what the front cost. Here we go... It starts out simple enough; remove the rear panels, remove the genny and waste water tanks - one grey water, one black water. The grey water tank was relatively empty.
Not so much for the black water tank... out rushed 25 gallons of putrid crap water that smelled like Satan's ass crack and splashed everywhere, including on us. This was supposed to be a NEW camper with nothing in it!
After several hours of cleanup, the work continued. The genny and tanks are out, and the fab can begin.
A new cross beam is installed and mock-up begins with the bracing.
Of course the CAD drawings sent to the Co. were not correct, so we had missing holes in the frame and hitch. Tear it all back out, drill the missing holes in the frame and modify the ones that didnt even accept the bolts. Reassemble and start to torque the bolts - first pull I made with the torque wrench I knew the specs were wrong. It called for 70 Nm and @ 48 the torque stopped rising and the brackets started deforming. The threads for the bolts was Micky mouse junk that would easily strip @ 70, so we convinced the engineer to go with 45 Nm.
Mock-up finished and torques documented on the hardware with a marker.
The end result!
I enjoyed this trip and job. Those MB engineer guys were so hung up on torque specs, whether drilling a hole in the frame would compromise safety or test results, ect they couldnt do this job because they couldnt think how to make something work when it wont. Super nice guys and very smart, but no real world skills whatsoever for fabrication or fixing something when it doesnt just bolt up. They were pleased with the work, and they want my team (boss and I) back again for something else in a cpl months.
We had to do some custom work on a 2019 Sprinter Winnebago camper. We had to remove the genny, waste water tanks, siding panels and other stuff. Then we installed these anti rollover outriggers so they can test this thing for what speed it will roll over cornering. There is another set that goes on the front that basically requires removing the bumper and bolting it on with 8 bolts that they will install themselves. Needless to say, things didnt go as planned. These rear outriggers we installed were custom built to the tune of $12,000, and I dont know what the front cost. Here we go... It starts out simple enough; remove the rear panels, remove the genny and waste water tanks - one grey water, one black water. The grey water tank was relatively empty.
Not so much for the black water tank... out rushed 25 gallons of putrid crap water that smelled like Satan's ass crack and splashed everywhere, including on us. This was supposed to be a NEW camper with nothing in it!
After several hours of cleanup, the work continued. The genny and tanks are out, and the fab can begin.
A new cross beam is installed and mock-up begins with the bracing.
Of course the CAD drawings sent to the Co. were not correct, so we had missing holes in the frame and hitch. Tear it all back out, drill the missing holes in the frame and modify the ones that didnt even accept the bolts. Reassemble and start to torque the bolts - first pull I made with the torque wrench I knew the specs were wrong. It called for 70 Nm and @ 48 the torque stopped rising and the brackets started deforming. The threads for the bolts was Micky mouse junk that would easily strip @ 70, so we convinced the engineer to go with 45 Nm.
Mock-up finished and torques documented on the hardware with a marker.
The end result!
I enjoyed this trip and job. Those MB engineer guys were so hung up on torque specs, whether drilling a hole in the frame would compromise safety or test results, ect they couldnt do this job because they couldnt think how to make something work when it wont. Super nice guys and very smart, but no real world skills whatsoever for fabrication or fixing something when it doesnt just bolt up. They were pleased with the work, and they want my team (boss and I) back again for something else in a cpl months.
Huge fucking plant, but not as big as BMW; just more convoluted to get anywhere on it. I had amazing authentic chicken tacos today from a street vendor truck that comes to the plant, slept in a 4 star hotel last night that was comped, but had the worst service I ever had from Texas Roadhouse last night for dinner. 
Dont speak of things of which you know nothing. Engineers design this shit in CAD programs where everything is static and does not change. Its funny they used the max torque load spec for the factory MB part # bolt without considering the material that was being clamped, or if the outsourced "nut" threads and brace material would withstand that torque. You say I know nothing, but after 43 years, I can tell when a fastener is going to fail by feel, and know to stop. GFYS with a torque wrench, dickhead. This vehicle is a test prototype and will never be sold, hence, no safety issues or other bullshit you spout.