So it's been awhile, but work has been getting done (the most we've been able to do so far.... Took all the windows out and rearranged them. Moved the emergency exit windows around and put in some window blanks in the areas behind the showers, closet and the wood stove location.
The blanks are made out of 16ga sheet metal (may be a little overkill), and had the edges bent in 1 inch. The tabs along the side will allow for attachment around the window frame. With the sheetmetal being as heavy as it was, the edges weren't 90 corners, they were round corners at a 90 degree angle, making it tough to get the screws started. The Tek self drilling screws are AWESOME.
Removed the Roof escape hatches and covered over with 16 ga sheetmetal. 1st drilled holes 3in apart 3/8" in along the outside edges of the sheetmetal. Then once on the roof, set the metal over the hole, and drilled a hole through each corner and then loosely screwed it to the roof (Tek 3/4" self-drilling, with neoprene washer). Once set, then used the sheetmetal as a templete and drilled holes into the roof. Unscrewed the sheetmetal, and then placed butyl taped along the edge under the drilled holes to seal between the roof and the panel. (FYI butyl tape seems to be good stuff, and all that I read was good about it, but cold butyl tape isn't very pliable). Then went back and used the tek screws and starting from the middle and working to the outside screwed the panel to the roof. Then caulked around the edge for good measure.
Took the strobe light off the back of the bus, and took the idea from Diesel Dan and WMKBailey, installed an RV vent. Traced the Vent, cut it out using the cutting wheel on the angle grinder, and set the vent in. With the roof curvature, and not wanting to bend the vent frame trying to make it fit, I built up the butyl tape under the vent screw holes and then used sheet metal screws with neoprene washers to hold it down. Caulked around it too. Looks good and it rained like cats and dogs today and no leaks.
Then we moved on to installing the insulation. Came across a good deal on 1.5" blue foam board on craigslist (was the perfect thickness for the roof and walls). Cut the insulation the correct demensions to fit between the roof braces and side braces. With the roof curvature, we then took each piece and cut it into 1/4 for the center section, for the more curved side roof parts, we cut each piece into about 6 pieces.
It was impossible to get each piece cut to fit perfectly, so each peice was trimmed to fit. Some gaps were left behind, so we used Great Stuff hold it in and fill the gaps. Trying to use the little squeeze nozzle was pointless, it was weak and wouldn't fit in the small areas well. Found that puttng on a rubber glove and used the can straight up would fit in the gaps and force the foam in.
To hold up the insulation while the Great Stuff dried, I made some simple braces. Cut firring strips to height, then used 3/8" Pex about 2.5' long screwed to the top of the firring strip. The flexible pex bent, yet applied some upward force.
Got all the insulation in except for the roof patch that I'm going to put a vent in.
Then we caulked all the holes in the floor shut.
Next up, using chalk to sketch out the layout and then start building walls, then insulating the the floor, shower pan and walls, bathroom walls and so on...... PROGRESS!!
By the way....vapor barrier between the insulation and the ceiling/walls...good idea or not?