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Old 05-29-2009, 04:33 PM   #11
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Re: Gator Tailgating Bus Build

Did the subfloor (felt paper, 1"x4" grid, 3/4 foam insulation, and OSB) before the buildout, and the wood floor after the build. With a short bus, it didn't take much at all - maybe $40 worth. My bathroom isn't even floored since it is elevated above a fenderwell. It just has a plywood floor. I'll probably throw some poly on it this summer.
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Old 05-30-2009, 08:28 PM   #12
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Re: Gator Tailgating Bus Build

Some new pictures added today. We ran some wiring, framed up for the panels that will go over the interior walls and after looking at the pictures and being halfway done figured out a better way to do it... the better ideas always seem to occur AFTER you are done. We came up with a weird way to frame so dont laugh, it isnt structural, only a place to adhere the luan panels. Also added more insulation and finished sealing up the exterior porch wall, I just hope that marine adhesive/caulk sticks as well to the back wall as it does to my fingers!

The Thomas body windows angle in, basically starting at the bottom of the window frame. I dont have a table saw so ripping 2x4s to fit it better wasnt an option. We ran a 1x2 just below the electrical channel then made a ladder type framework out of 2x3 on the straight areas. When you put the panel up it is almost straight up and down and the panel will butt the channel without sticking out at all, almost a smooth transition. Im doing the other side different so I'll post some pictures of the tomorrow. The insulation isnt taped or anything and has some gaps because it is mainly for sound reduction. If it blocks out some heat, that would be great too.

Anyone ever stained luan panels? The best information I could find is to spray a dye stain, washcoat then tint stain, and honestly I dont know what any of that is but Ill figure it out if that is the right way to do it. If it is as bad of a wood to finish as what I have read (Im not a carpenter, painter or wood finisher so it has to be simple) they have the same thickness oak panels for $9 more each.
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Old 05-31-2009, 07:57 PM   #13
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Re: Gator Tailgating Bus Build

Added a few more today http://s626.photobucket.com/albums/tt34 ... s/?start=0 . Put one window frame together to see how the black and the tint would look, very happy with how it all turned out. Finished cutting the old camper door down and redoing the bottom flange so it will fit on the rear porch. Ended up taking about 4" off the door and frame. Cleaned everything up some then removed and capped the front pupil warning lights. I decided to cap them on the inside and then fill the gap with body filler to make it flush and leave no sign of the old lights ever being there.
There are some pictures of how I did this in photobucket. Here's the steps
Cut some blanks a little larger than the hole with a circular saw and abrasive blade out of old metal exterior skin that was left from the porch. Traced the inside of the old lights rubber gasket and applied marine adhesive/sealant just on the outside of the line so it would seal right along the edge of the hole. Then put them (do one at a time) in place from the inside and screwed a self tapping screw through a 1x2 to pull the blanks tight against the old light holes. After it is set Ill remove the braces and use body filler to eliminate any traces of lights being there. A few tips, it would be alot easier with 2 people, one holding on the inside, other on the outside. Instead of 1x2 use some old thin gauge angle (i.e. drip edge) if you have it and some metal stud self drilling screws for the brace. The 1x2 and larger tek screws were difficult to use. Also, pre-drill the screws for the brace before you try to put the blanks up, if you are by yourself put an extra screw without a brace so you can hold onto the blank from the outside.

Ill paint the door frame tomorrow and install it on tuesday. Have to finish framing the walls, still torn between putting the laminate floor in before or after the build out. I am really worried about it not floating anymore and buckling or having to tear it out for whatever reason and becoming a nightmare. Has anyone put this type of floor in after framing?
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Old 06-05-2009, 07:14 PM   #14
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Re: Gator Tailgating Bus Build

A little more done tonight and some new pictures up. The back door is cut down and in place and started on the roof AC install. I had a front hatch that was sun rotted, cracked and leaking so it came out. Water kept seeping out onto the roof from under the rail so I drilled a hole on the inside of the bus just below the rail and water came pouring out, something that I will need to look into. After it is fairly dry under there I am thinking about drilling some holes in the roof rail and injecting some expandable foam in there to fill the cavity. Took some of the leftover steel that was cut off of the back and make a filler panel with a 14x14 hole cut into it. Cleaned off the old butyl tape, painted the old hatch opening with rust converting primer then finished with white rustoleum. Painted the the two filler panels and they are now sitting to dry until tomorrow. The hatch is larger than the trim ring on the inside so dont use that to cut your upper panel. The new panel will be adhered and sealed with west marine 8200 and a few self tapping screws will go in to retain it. We will make bracing out of 2x2 square tubing and weld in place after the top plate is put on. Should go pretty smooth but will find out tomorrow! I got some pictures of how we are doing the AC in case anyone else wants to do the same.
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Old 06-05-2009, 08:16 PM   #15
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Re: Gator Tailgating Bus Build

Just FYI... if you inject foam into the holes, make sure you don't do too much, otherwise it may blow out or warp the space. Expanding foam is really good at that!
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Old 06-06-2009, 08:53 PM   #16
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Re: Gator Tailgating Bus Build

New pictures up! A/C mounted today, kind of a pain. Ran a 12v wire across the bus before the A/C went in for lighting on the other side. Mounted water fill, outside coax cable and electrical boxes and back portch lights. The AC inside panel doesnt sit flush due to the curve in the roof, its in now and works but it will bother me enough to try and fix it later. Anyone have any easy ways to fix this short of trimming the plastic? We stuck a standard 3 prong plug on the end of the romex and ran it off of a generator for a little while. It definately will cool this bus no problem.

http://s626.photobucket.com/albums/tt348/gatorbus/
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Old 06-17-2009, 09:27 PM   #17
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Re: Gator Tailgating Bus Build

A few more pictures up. Got the rough plumbing in, cable and elec, insulated the back wall, started the rear railing and got one interior panel up. Finally got the new rubber for the windows in from a Thomas dealer and started reassembling, PITA. My friend that was helping me hurt his back on saturday moving the generator so not too much has gotten done since.

Saw some vinyl resilient plank style garage flooring at Home Depot. It is failry thick and plastic feeling with a diamond tread pattern. Anyone else seen this stuff? It looks like it will fit the bus perfectly.
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Old 06-18-2009, 07:40 PM   #18
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Re: Gator Tailgating Bus Build

Nice back door. Was that a regular security door, or an RV door?
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Old 06-18-2009, 08:07 PM   #19
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Re: Gator Tailgating Bus Build

It came off an old travel trailer with a rotted ceiling. I had to cut it down some and it still needs a little tweaking.
Got the porch rails up today and a few other odds and ends. Forgot my camera at home so Ill post some new pics of it tomorrow.
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Old 06-28-2009, 05:28 PM   #20
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Re: Gator Tailgating Bus Build

New pics up! The rear railing is done and exterior is ready to start paint prep. Framed some more interior walls the ran out of lumber, toilet flange in and some other misc things. Got a roof vent cap and 36 gal waste tank at the house that Ill put in here pretty soon. Check out the pics http://s626.photobucket.com/albums/tt348/gatorbus/
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