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Old 09-30-2014, 12:22 AM   #231
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Re: Journey Begins - 1988 Crown Conversion

MORE WALLS GOING UP
We have waited so long for this moment. Things are moving quicker this week. We are getting the walls up and making minor adjustments to the layout as we figure out we have an inch extra here and an inch less than we thought there, etc. I can't say enough great things about this wood paneling from Ikea. It is just looking great. I should have pictures late this week or early next week showing the side panels and some of the furniture installed.



Notice how the wood is curving to follow the form of the Crown's roof.




The walls will be insulated with spray foam.
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Old 09-30-2014, 09:17 AM   #232
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Re: Journey Begins - 1988 Crown Conversion

I know spray foam makes the wall stronger, but what about using cotton or wool batting? They are much better for sound control.

+1 on the Ikea paneling looking awesome. I figure a lot of my interior will be coming from there.
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Old 09-30-2014, 08:15 PM   #233
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Re: Journey Begins - 1988 Crown Conversion

We have a roll of the closed cell foam sheets with aluminum on both sides. That will be going in first and then the foam insulation, and then another layer of the closed cell foam sheeting before putting the back side of the wall up. It should help deaden the noise. You are smart to look at the Ikea wood paneling and cabinets. They are very well made and relatively cheap when compared to buying custom cabinets. On the other hand, if you have great wood working skills, Ikea is much more expensive than building it all from scratch. I happen to be the type of guy with absolutely zero. . . . .nada. . . . .zilch. . . . .wood working capabilities. Somewhere up in my attic I have the really ugly jewelry box I made in wood class in junior high. Took me all semester and is a sad testimonial to my lack of skills in this area. Manage a $500 million budget, CHECK. Build a cabinet from scratch, DEAD ON ARRIVAL. Ikea is my salvation. Also, the European Birch takes such a wonderful stain. The grain and everything is just perfect. We tried to duplicate it with American Birch and it was just not the same. It did not look as elegant and beautiful as the European Birch. We have been getting all of our wood paneling in the bargain bin. It is 50% to 60% off due to minor scratches on one side. We just put the scratched side against the wall instead of facing out. Perfect! We have had to go several times to get all the wood we needed as I did not want to pay full price and each time they had only one or two sheets of the wood paneling.
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Old 09-30-2014, 09:30 PM   #234
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Re: Journey Begins - 1988 Crown Conversion

Do What Works...for you!
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Old 10-06-2014, 11:24 PM   #235
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Re: Journey Begins - 1988 Crown Conversion

How hard was it to remove the original headliner and reinstall it? Which rivet tool did you use? Thanks!

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Old 10-15-2014, 01:34 PM   #236
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Re: Journey Begins - 1988 Crown Conversion

It was not that hard in terms of skill. Just time consuming with over 1,500 rivets. Crown headliners are used to help support the rigidity of the roof structure and help strengthen the ability of the roof to handle roll overs. Crowns built from the late 70's on were built to handle the bus being dropped from a height of 25 feet on its roof and the roof would not collapse. The overlapping headliner panels are an integral part of that strength. I have seen some skoolie conversions that modify or even remove their metal headliners. A structural engineer told me not to do that. My concession was to put a rubber tape on the structural roof ribs before putting the headliner back up to try and create a thermal break. The overall strength was retained and now I had an insulated barrier (I used spray insulation closed cell foam) to the cold and heat. I also purchased rivets that had a very low profile. That was because I wanted to put a faux leather headliner up on the roof and I did not want the rivets to show through the smooth leather covering.
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Old 10-15-2014, 01:59 PM   #237
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Re: Journey Begins - 1988 Crown Conversion

STAINLESS STEEL SHOWER STALL
We really love the look of vintage AirStream trailers and their stainless steel showers. We wanted to duplicate that look. In my research I learned that you don't want to wimp out on the quality of the stainless steel sheets. You absolutely need high chromium content steel to minimize any possibility of rust. The stainless steel sheets were over $1,000.

The floor pan is also stainless steel. The key is to make sure that the steel walls fit inside the floor pan and not outside. You don't want any possibility of water getting through any seams or cracks.

Below are pictures of the shower enclosure. We really wanted the shower larger. However, it would have taken up too much floor space and screw up our other wants. It is also a custom size 27" x 31". The ceiling is one piece that exactly matches the curve of the Crown's ceiling and sides. That was a pain. This material is very expensive, so redoing mistakes was not an option. We used a cardboard template to get the exact curve of the sides and roof.

It has not been placed in the bus as yet. That comes next. It will require the windshield to come out of the bus. it is the only way to get the finished product into the bus due to its size. The problem was doing any welding inside of the bus. We have already put in the faux leather covered headliner, the wood floor, some of the side wall paneling, etc. Welding inside the bus would probably damage what we have already done. So, the welding is taking place outside of the bus, and then the windshield will be removed and the shower pushed through the opening. I kind of feel like the guy that builds a large boat is his basement and then realizes that there might be a problem getting it out of the basement. On the other hand, the final shower size had to wait as we finished other aspects of the actual placement of sofas, cabinets, walls, etc. We decided to move forward with the other aspects of the interior and then decide at the appropriate time what the actual shower size would need to be. Thus, the need to take out the windshield to get the shower into the bus.

The protective tape is still on much of the steel












We are planning on a frameless glass shower door.
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Old 10-15-2014, 02:19 PM   #238
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Re: Journey Begins - 1988 Crown Conversion

DROOL.
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Old 10-15-2014, 03:38 PM   #239
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Re: Journey Begins - 1988 Crown Conversion

I seriously love this bus.. and I am drooling over your generator set up .. at almost $10k just for the generator I would guess you mean serious business!

http://www.electricgeneratorsdirect.com ... p6600.html

I might wire mine expecting one of these and wait until the last minute when I am ready to move into the bus to purchase it. Living in the bus I'll save that much in just a few months so ...
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Old 10-15-2014, 03:51 PM   #240
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Re: Journey Begins - 1988 Crown Conversion

How does one go about getting someone to build a custom thing like that ? What type of business?
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