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Old 11-15-2019, 01:43 PM   #21
Bus Nut
 
Join Date: Jul 2017
Posts: 819
Year: 1993
Chassis: IH 3800
Engine: DT360
Rated Cap: 66
Here's the current plan for the tail...

Green - Bus Frame
Red - 6" channel main runners for tail - Inside the "C" of the bus frame
Yellow - 4" channel (open to suggestions) for supports/gussets - Outside the "C" of the bus frame

Rough dimensions to give me an idea of material needed. This provides a 42" tail, 24" of ground clearance to the bottom of the tail... and a 9* departure angle. If the departure angle ever becomes an issue, I'll consider pushing the rear axle back but I doubt it'll be a problem. Don't plan on off-roading the big bus.


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Old 11-17-2019, 01:05 AM   #22
Bus Nut
 
Join Date: Jul 2017
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Year: 1993
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Rated Cap: 66
Progress being made. Only had an hour to work today but got a good start on getting the seats out and a peak at the mess to come.

Gonna have a lot of sheet metal to repair but I knew that going in.

More to come soon.

Btw.. if anyone is looking for cheap cutoff wheels, check out benchmark abrasives. $1 each for 6" wheels and I haven't worn one down yet on getting the seats out.Attachment 39312Attachment 39313Attachment 39314Attachment 39315Attachment 39316Attachment 39317Attachment 39318Attachment 39319Click image for larger version

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Old 11-19-2019, 08:23 AM   #23
Bus Nut
 
Join Date: Jul 2017
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Year: 1993
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Engine: DT360
Rated Cap: 66
Been using the app... not a fan of how it posted the pics on the last post so gonna repost the pics from that...











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Old 11-19-2019, 08:31 AM   #24
Bus Nut
 
Join Date: Jul 2017
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Year: 1993
Chassis: IH 3800
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Rated Cap: 66
Picked up the steel for the main frame extension.








I believe we have decided to skip the "beaver tail" on the back. Too much of a hit to the departure angle.


However, with using 6" channel, we'll be running it towards the top of the 10" frame on the bus. At the furthest point, we only lose 1* of departure angle with a 3' 6" tail extension (which would make our tail the same length as the local big buses).


Also, we'll be "dove tailing" the rear extension.



Basically that means from an overhead view, the tail will look like this....


l - - - - l
\______/


This will give us more wiggle room with the tail sing.


Anyways, more to come once I get the rest of the seats out.
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Old 11-19-2019, 11:20 AM   #25
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Location: Dawsonville, Ga.
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Year: 1999
Coachwork: Genesis
Chassis: International
Engine: DT466/3060
Rated Cap: 77
Quote:
Originally Posted by Mr4btTahoe View Post
Progress being made. Only had an hour to work today but got a good start on getting the seats out and a peak at the mess to come.

Gonna have a lot of sheet metal to repair but I knew that going in.

More to come soon.

Btw.. if anyone is looking for cheap cutoff wheels, check out benchmark abrasives. $1 each for 6" wheels and I haven't worn one down yet on getting the seats out.Attachment 39312Attachment 39313Attachment 39314Attachment 39315Attachment 39316Attachment 39317Attachment 39318Attachment 39319Attachment 39320
I use these. Buy them when they are on sale for $5 for 10. What tool are you using 6" discs on?

https://www.harborfreight.com/pack-o...tal-45430.html
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Old 11-19-2019, 11:33 AM   #26
Bus Nut
 
Join Date: Jul 2017
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Quote:
Originally Posted by o1marc View Post
I use these. Buy them when they are on sale for $5 for 10. What tool are you using 6" discs on?

https://www.harborfreight.com/pack-o...tal-45430.html



A 6" Metabo angle grinder. So far, loving the cut off wheels from benchmark abrasives. Cheaper than HF and seem to last longer.
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Old 11-19-2019, 12:07 PM   #27
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Join Date: May 2016
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Quote:
Originally Posted by Mr4btTahoe View Post
A 6" Metabo angle grinder. So far, loving the cut off wheels from benchmark abrasives. Cheaper than HF and seem to last longer.
I am going to have to give those a try.

I bought a Norton cutoff disc and used it for a couple of ods and ends a few years ago then put it on the shelf until I started on my roof raise.

I needed to make a cut all the way across the roof. I got a bit over half way across and the old Norton disc was done for. I finished the cut with HF discs. Four of them....

The portion that I cut with the Norton was much straighter than the portion cut with the HF.
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Old 11-19-2019, 12:20 PM   #28
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Great project. I have seen your work on your last bus, so I bet this one will be outstanding.
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Old 11-19-2019, 05:57 PM   #29
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Slow progress 30 minutes at a time... But oh well.





One side is out and swept up.. started on the other side. Might have them all out by Thursday.
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Old 11-20-2019, 11:28 PM   #30
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Join Date: Feb 2018
Location: Golden Valley AZ
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Year: 1993
Chassis: ThomasBuilt 30'
Engine: need someone to tell me
Rated Cap: me + 1
Quote:
Originally Posted by Mr4btTahoe View Post
Here's the current plan for the tail...

Green - Bus Frame
Red - 6" channel main runners for tail - Inside the "C" of the bus frame
Yellow - 4" channel (open to suggestions) for supports/gussets - Outside the "C" of the bus frame

Rough dimensions to give me an idea of material needed. This provides a 42" tail, 24" of ground clearance to the bottom of the tail... and a 9* departure angle. If the departure angle ever becomes an issue, I'll consider pushing the rear axle back but I doubt it'll be a problem. Don't plan on off-roading the big bus.


What about dips and sloped driveways? Maybe grind an angle on the bottom of the end rail and/or add some air springs to rear axle to lift the frame when needed?
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Old 11-21-2019, 09:16 AM   #31
Bus Nut
 
Join Date: Jul 2017
Posts: 819
Year: 1993
Chassis: IH 3800
Engine: DT360
Rated Cap: 66
Decided I don't really want to cut up the whole bus with cut off wheels... so after some research, ordered an El-Cheap-O plasma cutter off e-bay.


Its a 50 amp pilot arc unit and it'll be here Tuesday for $240. The reviews I've seen have been mostly good. A couple DOA which were handled but mainly good... cuts up to 1/2" cleanly and will cut sheet metal like butter.


This will make cutting the body apart much easier.


Anyways, going to get the rest of the seats out tonight and possibly get the rubber floor pealed up. We'll see.
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Old 11-21-2019, 10:37 AM   #32
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Join Date: Feb 2018
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Quote:
Originally Posted by Mr4btTahoe View Post
Decided I don't really want to cut up the whole bus with cut off wheels... so after some research, ordered an El-Cheap-O plasma cutter off e-bay.


Its a 50 amp pilot arc unit and it'll be here Tuesday for $240. The reviews I've seen have been mostly good. A couple DOA which were handled but mainly good... cuts up to 1/2" cleanly and will cut sheet metal like butter.


This will make cutting the body apart much easier.


Anyways, going to get the rest of the seats out tonight and possibly get the rubber floor pealed up. We'll see.

you know that you need an air compressor and dryer, right? fire protection?
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Old 11-21-2019, 10:46 AM   #33
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Engine: Cummins ISC (8.3)
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Quote:
Originally Posted by kidharris View Post
you know that you need an air compressor and dryer, right? fire protection?
+1

Plasma cutter or not, we should all have properly rated fire extinguishers handy when working on our buses. I have had the black goop in the front cap catch fire a couple of times while cutting with my angle grinder and when welding.
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Old 11-21-2019, 11:12 AM   #34
Bus Crazy
 
Join Date: Feb 2018
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Quote:
Originally Posted by PNW_Steve View Post
+1

Plasma cutter or not, we should all have properly rated fire extinguishers handy when working on our buses. I have had the black goop in the front cap catch fire a couple of times while cutting with my angle grinder and when welding.

I've had numerous small fires over the years including burning 2 shirts off of me. I could see a fire out of the corner of my eye and when I turned to look, the fire moved with me. Turns out that is a good indicator that you are on fire. LOL
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Old 11-21-2019, 11:24 AM   #35
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Join Date: Jul 2017
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I happen to have all of the above.

I've been fabricating for years, just never wanted to spend the coin for a hypertherm or esab cutter. Then found that these cheapies are decent enough and figured it was worth a gamble. I'd more than likely spend more than that on abrasives anyways on this project.. but anyways.
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Old 11-21-2019, 06:59 PM   #36
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Join Date: Jul 2017
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I think I may be in the running for rustiest bus 2019. Lol

Seats are out and a bit of the floor is up. The entire aisle way is pretty rough. I guess it's because the floor was 3 separate pieces of rubber which allowed moisture from wet shoes over the years to get under it.

Anyways..









Honestly I was expecting worse in the rear but wasn't expecting the rot full length in the aisle. Won't be too bad to clean up and patch but oh well.

More to come soon
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Old 11-21-2019, 07:24 PM   #37
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I think I may be in the running for rustiest bus 2019. Lol

Not even close, I see rusty floor. Musicgenius has massive rusty holes.
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Old 11-23-2019, 06:08 PM   #38
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Showed up early and decently well built. Will give it a test run tonight or tomorrow.Click image for larger version

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Old 11-26-2019, 06:30 PM   #39
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Well after testing several ways to pull rivets, I decided the air hammer method works best/cleanest. Chisel must be sharpened to a point and plan on resharpening often.

Anyways... Got one of the ceiling sheets down and the old insulation removed... Then the mess cleaned up.

Plans are to finish gutting the interior over the long weekend and hopefully start disassembling the rear in preparation to move it forward 10'.

Anyways..





This is the method I used.

https://youtu.be/7NEs9i8Bmoo
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Old 12-04-2019, 09:54 AM   #40
Bus Nut
 
Join Date: Jul 2017
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Progress is slow but oh well. Pulling a panel an evening as I have time between work and work. I've got it down to 45 minutes from when I go out to the shop and kick on the compressor... til I'm back inside. That includes clean up of the old insulation and such.

Down to 1 panel left that has to come down. Then I'll start on the walls. Will hopefully order materials to build the new rear wall sometime next week or so. We'll see.

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