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Old 01-16-2015, 10:46 PM   #281
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Re: Journey Begins - 1988 Crown Conversion

PASSENGER WINDOWS BEING LOCKED DOWN AND INSULATED
Early on we decided that we did not want this bus to totally lose its bus identity. We intend to use the bus as a rolling training and demo lab for our transportation software company. We want it to still look like a bus on the exterior. That meant keeping the passenger windows.

The first thing we did is check out every single window. Any imperfections (scratch, delamination, etc.) meant that the window was replaced. I had picked up about 20 windows from a client school district that was crushing their Crowns. So, there was no need to buy new ones. We then had them all tinted using the high end 3M tinting (see earlier posts).

However, some of the windows will be behind cabinets and our stainless steel shower. We needed to make sure that the windows were secured and insulated. Further, we needed to make sure that the windows that would be closed off and insulated did not look different from the outside (white insulation against the glass would show). So, all the insulation was painted black on the side facing the windows so it would not contrast with the darkened tinted windows on the rest of the bus.

The pictures below show you what we did. First, we locked the windows and screwed them into the window frames. Then we installed the insulation.



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Old 01-16-2015, 10:55 PM   #282
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Re: Journey Begins - 1988 Crown Conversion

NAVIGATION CHAIR PLACEMENT
This was a very difficult decision. My wife originally did not want to sit over the wheel well. However, it totally screwed up the passenger side configuration for our cabinet that is going to house the electrical fireplace and the 40" pop up flat screen monitor. If we placed her navigation chair behind the wheel well, then we had to say goodbye to the 40" flat screen.

The solution was to engineer a frame that went directly over the passenger side front wheel well. This was critical as the chair must be properly secured in the event of a crash. My wife kept pointing out her reluctance to have the chair tearing out of the floor and sailing through the front window. Picky, picky, picky!!!

We designed a frame that was then checked out by engineers. This thing is solid. It is secured both to the side rails as well as completely through the bus floor with metal plates under the bus to spread out the pressure if the bus was in an accident. The navigation chair is then attached to the frame.

Picture is below.
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Old 01-16-2015, 11:00 PM   #283
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Re: Journey Begins - 1988 Crown Conversion

NAVIGATOR CHAIR INSTALLED
The Navigator chair has now been installed. It is an electric one with recliner, footrest, lumbar support, etc. It is identical to the driver's chair except it does not have air ride suspension. It has extra cushioning and a double set of springs to make the ride easier. The material is ultra leather.

The wheel well will be covered in the same coin rubber flooring that you saw in a previous post.

The picture is below.
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Old 01-17-2015, 08:31 PM   #284
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Spectacular job so far.
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Old 01-19-2015, 10:31 AM   #285
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You have done a great job on your conversion.

I was looking at your trailer hitch.

I think you have forgotten a very important part of the hitch support.

Crowns, unlike every other yellow bus made, does not have any frame behind the fuel tank. Which means there is nothing structural in the trunk area. This was designed specifically as a crunch zone so that in an accident where the back of the bus was hit the trunk could crush without passing on the crunch into the passenger compartment.

Because there is nothing back there, extending the frame rails is the only way you can pull anything with a Crown.

But you also need to do something to support the downward thrust of the hitch weight.

The way in which you have your trailer hitch installed is very stout for fore and aft but you have only sheet metal supporting the up and down.

You are going to need to figure out some way in which to support the tongue weight or you will find yourself one day with your bumper on the ground and your trunk ripped off below the rear window.
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Old 01-19-2015, 05:59 PM   #286
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This setup was reviewed by an engineer. I will revisit to see what they all think. Thank you for the warning. Your comments make perfect sense to me. I will find out and let everyone know what we are doing.
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Old 01-21-2015, 02:29 AM   #287
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Engineer Tells Me All is Well

The designer of the trailer hitch setup tells me that the additional beams you could not see under the bus make everything OK. An earlier post in this forum showed those beams that were installed inside the trunk area an work in conjunction with the beams under the bus to create a solid hitch assembly. I have been assured then everything has been designed to prevent exactly what was potentially outlined. It is solidly constructed and will not create a problem with the trunk area and bumper getting ripped off. I was told that if the beams under the bus were the only additions then the concerns would be valid.
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Old 01-21-2015, 04:28 PM   #288
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Nice job!! Keep up the good work!
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Old 01-21-2015, 11:16 PM   #289
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Re: Journey Begins - 1988 Crown Conversion

ELECTRICAL EVERYWHERE

The electrical is starting to come together. I haven't added it up, must it seems like miles of electrical in the bus. Everything is getting labeled. We learned from our fellow skoolies.



Electric Central


This bus will have 50 amp service.
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Old 01-22-2015, 09:58 PM   #290
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As a side note...the last I checked, the vast majority of RV campgrounds as well as parks are still mostly 30 amp service. Can anyone else add to this?
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