Building Comfort Eagle (1986 Gillig Phantom) - Page 6

ComfortEagle · 12-24-2018, 07:21 PM

I decided to start putting all that free oak to work today. I hope it will be a nice contrast to all the black painted wood.

The big opening on the left will have some type of black metal grate covering the new dashboard heater/defroster, with "cubbies" on the right...

ComfortEagle · 01-18-2019, 06:16 PM

I finally feeling like the end is in sight in terms if finishing the dashboard. See the dashboard link in my signature for more if interested...

I also did a little "VIN Plaque" project this week... The original VIN tag was basically just a piece of metal tape glued to the fuse panel cover above the driver seat. I removed the Gillig emblem from it's original location above the windshield.

I cleaned up the Gillig Emblem and had a local trophy shop make a new VIN tag (and of course a Comfort Eagle tag). Once I clean up and repaint the fuse panel door I will mount the new VIN plaque.

somewhereinusa · 01-18-2019, 06:52 PM

Love the VIN tag. I may have to copy that.

Ninjakitty · 01-18-2019, 07:55 PM

Looks great! I'm about 2 days from my dash makeover. I hope it turns out a 1/10 as nice

EastCoastCB · 01-18-2019, 07:58 PM

Quote:

Originally Posted by Ninjakitty

Looks great! I'm about 2 days from my dash makeover. I hope it turns out a 1/10 as nice

Same here. Except I'll be doing good to start my dash project by summer!

ComfortEagle · 02-03-2019, 07:42 AM

For those not following my ever growing list of "sub-threads", I recently decided to do a fuse box makeover. Before and after pics are below. For more details and helpful "lessons learned", the link is here: fuse box.

Before:

After:

I also temporarily installed our 4K Dwarf wood stove in the bus. It's been pretty cold here in MD lately (not Yukon Cornelius cold...) and the wife wanted it out of our living room where it had been "on display" for many months.

It will eventually be going up front near the front door, but for now it's vented thru a hole I cut in the rear roof hatch. I will be starting another sub-thread with more pics and details...

ComfortEagle · 08-12-2019, 03:29 AM

Wow, 6 months since I've updated this thread...

It's been a productive summer so far. I have been focusing a lot of energy on getting the roof finished and getting the bus fully weathered-in and leak free before the weather turns cooler again.

Below is a current pic of the roof. I permanently mounted the chimney for the wood stove, installed new LED clearance lights, and of course the Suoerstrut racks for the solar panels and some decking.

Rather than using any specialized roof coating, I chose to repaint the roof with some gloss white rust inhibiting enamel. Literally the entire roof will be covered by either solar panels or decking.

I have also finally started re-sealing the driver side windows. Once these 4 are done, only 8 more to go...

Still not much going on inside the bus. I did put down most of the subfloor. I went with 1/2" plywood on top of the very healthy existing 3/4" nuclear strength Gillig plywood floor. I will be insulating most of the floor from underneath.

Also been finalizing the interior design and and sourcing the actual material and products we will be using.

I picked up this couch at Bob's discount furniture. If you look you can see that in this pic I have already removed one of the arms. I will be using some custom oak arms from an old antique chair. Since this pic, the couch has been completely gutted. All that is being reused are the bottom cushions and the back portion with the back cushions attached.

And finally, this spray foam kit showed up last week. I have a lot of work to do before I will be ready to suit up and get spraying, but I have designated August as "spray foam month" and it shall be done. With this spray I will be focusing on the roof and walls. I will be buying at least one more kit to finish out the rest of the bus...

Once the roof is completely done, spray foam and all, I will get the mini split plumbed up, and then install the solar panels and finally move the battery pack onto the the bus...

EastCoastCB · 08-12-2019, 07:36 AM

Very cool, man. How yall been?

TJones · 08-12-2019, 08:04 AM

Looks good. How did you attach your super strut to the roof?

Ted

ComfortEagle · 08-12-2019, 08:12 AM

Quote:

Originally Posted by EastCoastCB

Very cool, man. How yall been?

Doing well; not spending much time on the forums, but highly motivated to get this bus done...

Heading up to New England in Sept. Gonna meet up with my brothers and go to Burlington VT for Grand Point North music festival. Gov't Mule (one of my favorite bands...) is playing on one of the days... Maybe next year I'll be able to take the bus to events like that; that is motivating...

I was at this show in Baltimore, it was awesome...

https://www.youtube.com/watch?v=2ri5Ew3xY38

EastCoastCB · 08-12-2019, 08:16 AM

Quote:

Originally Posted by ComfortEagle

Doing well; not spending much time on the forums, but highly motivated to get this bus done...

Heading up to New England in Sept. Gonna meet up with my brothers and go to Burlington VT for Grand Point North music festival. Gov't Mule (one of my favorite bands...) is playing on one of the days... Maybe next year I'll be able to take the bus to events like that; that is motivating...

I was at this show in Baltimore, it was awesome...

https://www.youtube.com/watch?v=2ri5Ew3xY38

I got to see Gov't Mule in Orlando a few years ago. Man they really put on a hell of a show!

ComfortEagle · 08-12-2019, 08:25 AM

Quote:

Originally Posted by TJones

Looks good. How did you attach your super strut to the roof?

The outer sections of superstrut are bolted to the structural cross members of the bus roof. I used wedges made of composite decking to adjust for the roof pitch. The center section is just bolted straight into the center roof structural support.

This section around the chimney is a little weird but shows the basics. Copious amounts of Dicor have been applied since this pic was taken...

ComfortEagle · 08-12-2019, 08:27 AM

Quote:

Originally Posted by EastCoastCB

I got to see Gov't Mule in Orlando a few years ago. Man they really put on a hell of a show!

I keep "threatening" my wife, telling her we are gonna follow Govt Mule around the country in the bus when I retire...

ComfortEagle · 08-17-2019, 06:38 PM

I pulled the last 8 windows today...

Getting these windows done is big deal to me. Completing the window reseal means I AM DONE grinding on the inside of the bus. It also means I am getting closer to making the bus water/weather tight.

Tomorrow the windows will be cleaned and resealed/reinstalled; all except the one I broke! Booger! That one will be off to the glass shop on Monday.

I also finished "Dicor-ing" the roof rack, and with one more coat of paint, the roof is done... And don't forget, August is spray foam month.

TJones · 08-18-2019, 02:15 PM

Quote:

Originally Posted by ComfortEagle

The outer sections of superstrut are bolted to the structural cross members of the bus roof. I used wedges made of composite decking to adjust for the roof pitch. The center section is just bolted straight into the center roof structural support.

This section around the chimney is a little weird but shows the basics. Copious amounts of Dicor have been applied since this pic was taken...

Thanks. I was wondering how you shimmied for the roof curvature.

Ted

ComfortEagle · 08-24-2019, 04:32 PM

I got all the windows re-installed, including the new panes from the glass shop, and just in time for some heavy rain showers. The bus is still not water tight... sucks. Once the gutters are re-installed, it should be better, but I definitely have more work to do with those windows.

In the meantime, "spray foam August" is slipping away. I had hoped to spray this weekend, but I am not quite ready. I did box out the rear wheel wells; not done yet but getting close.

The center section between the wheel wells will be part of the platform/step to the bed, but will have a hinged lift up door and storage underneath. The space behind the box-outs will be under bed storage...

Once the front wheel wells are boxed, I should finally be ready to "get the foam on".

ComfortEagle · 08-31-2019, 04:48 AM

Finished up the last of the subfloor installation, and am almost done boxing the front wheel wells.

One design element of the Gillig Phantoms that I am not in love with is the slope of the floor near the front on the bus. Not sure if other buses share this trait. If you look at the rails on the wall, behind the front wheel wells you will see them start start to slope down towards the front. This presents additional challenges when building up front.

And then there is the big steel cockpit floorpan.

I chose not to put subfloor between the driver seat and the pan. I hope to mitigate some of the heat/cold transfer by insulating the pan from underneath and coating with spray on undercoating or bed liner...

If the weather (and my back) hold out, I WILL get the spray foam done over this long weekend. Speaking of weather I hope that ECCB and all of you other Floridians are getting safe for the upcoming storm...

ComfortEagle · 09-02-2019, 02:39 PM

Did the spray foam today; details are here

ComfortEagle · 09-15-2019, 09:11 AM

The insulation is all trimmed, and the bus is all clean. I am encouraged.

In the meantime taking a break here in beautiful Burlington VT at Grand Point North 2019. Great bands yesterday and Govt Mule tonight...

Here is a video I shot from last night's show...

https://www.youtube.com/watch?v=dXpg...&start_radio=1

ComfortEagle · 09-29-2019, 07:43 PM

One more pic with all rigid foam installed

I did some Bondo work here on the old flashing light holes; still some work to be done, but not bad...?

And finally... I cleaned the bus and put a final coat of paint on the roof.

Here it is after cleaning but BEFORE the last coat of paint

And here are a few shots (crappy shots) of the finished roof. Although I must say, it does look like a boat hull, no...?

You may also like: