Chinook

FROM A SKETCH TO REALITY

The “Ugly Duckling” rebuild began after extensive deficiencies were identified in the original construction. Initial inspection revealed inadequate structural support, poor load management, and improperly integrated fiberglass components. As a result, a complete interior demolition was required to expose the primary structure and assess all load-bearing elements.

To correct these deficiencies, a fully welded steel reinforcement cage was designed and installed. The cage was integrated into the existing chassis to provide a continuous load path and to properly support the fiberglass shell, which previously functioned without sufficient structural backing. This reinforcement significantly increases torsional rigidity and overall structural integrity.

The Chinook’s floor system was completely re-engineered. A new subfloor structure utilizing steel framing and aluminum panels was fabricated and installed to improve stiffness, distribute loads evenly across the chassis, and eliminate flex present in the original design.

Additionally, the chassis was extended by eight inches and structurally reinforced. This modification was engineered to improve longitudinal weight distribution, reduce rear overhang stress, and enhance vehicle stability under both static and dynamic loading conditions.

With these corrections, the platform now meets proper structural standards. The primary load-bearing system has been rebuilt to function as intended, establishing a safe and stable foundation for all subsequent phases of the build.