Long 3 days of working on the bus. Luckily I had a helper. She works her butt off and never complains. Totally thankful for that.
Got right to cutting the roof and the rear section out:
Help from the engine hoist:
Then the side panels as they will be replaced by tool cabinets / storage bays:
Then after flap wheel grinding / air chiseling the rust flakes off of the floor I found two main areas that had rusted through and I'm a big believer in doing it right so you only have to do it once.
Cut the pieces out, tack welded in the new ones and off to Metal Blast. I will be sealing everything from the bottom in the near future - before the underneath gets Spray Foamed.
As mentioned previously I purchased it through OnPoint Distribution. Awesome product and after following the instructions I applied a heavy coat of Rust Bullet. Great stuff, totally looking forward to the finished product.
Time wasn't on our side so I'll have to scuff it up and do a second coat later before being done with the Rust Bullet as per the instructions:
As that set up, I routed the exhaust out just behind the passenger dual tires. That way I can see any issues from the exhaust much easier. It will also help down the road for tuning the Injection Pump after the turbo is mounted to make sure it isn't smoking and wasting fuel.
The goal was to get the back of the bus in place before the end of the weekend and we did just that. I'll have to buy some 9/32" rivets in a big quantity and a rivet gun that will handle that size but for now it has some self tapping screws holding it in place:
Finished cleaning up the metal that will be reused to cover 21 of the 26 windows that were removed and called it a day.
But first we let it warm up for a long time and took it for a short but very fun little rip down the service road.
I think the name Ramrod is fitting for this bus. Why? It's big and bad ass (akin to a Hot Rod build but not sporty of course), animals better stay out of the way, and Super Troopers is awesome. Bedtime for me.. right Meow!