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Old 06-06-2014, 12:33 AM   #61
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Re: RV There Yet? The tale of a 92 BB TC2000

I use a de walt, simply because that is what was available...I have used my small SOG and a number of other sharpish edged items.... it is foam not armor... use whatever you can find, I am just saying there is no need to bring electricity into this.
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Old 06-10-2014, 11:09 PM   #62
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Re: RV There Yet? The tale of a 92 BB TC2000

Yeah I tried the box cutters and then realized I could cut it in 1/4 the time with a jigsaw. My foam was 2 inch thick so not as easy as the iso sheets. Anyways that portion is done. I have to insulate the front cap and the end cap then the ceiling panels go in. I finished the plywood strips tonight and sold my fridge and water heater which paid for my materials for the ceiling finish.


this is one of the roof sections I am adding a vent fan to
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Old 06-11-2014, 03:52 PM   #63
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Re: RV There Yet? The tale of a 92 BB TC2000

looks great!
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Old 06-11-2014, 08:48 PM   #64
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Re: RV There Yet? The tale of a 92 BB TC2000

Another day another issue. Anyone have any pointers on getting the luan to closely hug the roof? At the top its a snug tight fit but on the side its a different story. Almost an inch gap in a place or two. I thought about cutting the blind side but it would risk breaking the board as it is only 3 plys.
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Old 06-12-2014, 09:44 PM   #65
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Re: RV There Yet? The tale of a 92 BB TC2000

WE figured out our error. We needed 1 more row of strapping that remains in the curvature. Cutting the boards and adding the roof vent took up all my daylight today.
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Old 06-16-2014, 11:18 PM   #66
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Re: RV There Yet? The tale of a 92 BB TC2000

Got the roof up and started on the walls. Step one was finding a way to remove unwanted windows. The original plan was to re seal and screw shut the windows behind walls and painting the glass. The main issue was the problem that would arise if a window behind a wall was to break. Major headache. So we called around for some steel prices. So after realizing I should have kept my steel from the roof I began looking for an alternative. I came up with this......




This replacement window panel is constructed with a fiberglass skin and 7/16 plywood. I pulled the window frame and removed the glass sections and then put the frame back together. Took measurements, cut the fiberglass with a special jigsaw blade and then cut a plywood blank the same size. I then took the end off the frame and slid the two back in where the glass was. I sealed it all up with Sika Flex 221. Added some more sealant to the window frame and put it back in the hole. I will take some more daylight pics of the whole process step by step when I get a chance to get back at it.

I also removed some of the extra wires and cleaned it all up while removing the exterior light monitor. Ended up with a pile of wire.
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Old 06-17-2014, 12:11 AM   #67
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Re: RV There Yet? The tale of a 92 BB TC2000

The Silkaflex was a good choice. Once cured, it can be painted with just about anything without fear of peeling or cracking under normal conditions. Before using the stuff to glue in my window blank outs I squeezed out several 3" long strips of Silkaflex, waited for it to cure then painted them and let the paint dry for several days. I next worked the painted strips of sealer various ways to see what happened to the paint coating. I found that whether I used latex paint, Rustoleum, lacquer primer or base coat clear coat, the worst damage I produced was cracking of the paint but no delamination.

I did discover that while Silkaflex 221 will stick initially to ABS plastic, polyethylene, poly carbonate and other waxy plastics it will loose bond strength after a week or so making it a no go for most tank repairs.

As you no doubt discovered, Silkaflex can be a mess to work with but is for the most part easily cleaned up with mineral spirits prior to the Silkaflex curing.
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Old 06-18-2014, 12:14 AM   #68
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Re: RV There Yet? The tale of a 92 BB TC2000

I used Sika Flex when I worked at Great Dane Trailers. I was responsible for the last row of rivets that attached the outer skin to the rear frame. At the very top there were a few different style plates that were attached and they were coated in the stuff. My uncle still works for them in the warranty department and told me they never have had any issues with the stuff under warranty. Naturally I went to the repair shop in town down the road from the old plant and picked up 4 tubes of the stuff. Its awesome. Its UV resistant, paintable, sandable and will never become rigid. I used it to seal up the roof hatches and to seal the new vent I added for the shower. I love it and a little goes a long way.
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Old 06-21-2014, 05:16 PM   #69
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Re: RV There Yet? The tale of a 92 BB TC2000

Hey Kenny, et al!

I'm picking up my bus next week and this is my very first post, although I've been reading all the great advice for months. I'm throwing this out here simply because our buses look remarkably similar and it appears you've put a lot of thought into this.

Here in Idaho my major concern is making the cabin comfortable during the extremes of 100 degree August days and sub zero January nights, so getting the insulation right is the most important thing I can think of.

My 27' unit actually has more room than I need, and I'm not concerned about head room since I'm 5'6" and live alone. My question is: Could I save time and labor, and still wind up with better walls if I didn't strip the existing walls to the steel? I'm thinking of putting a vbl, foam, and wood paneling directly onto the existing interior.

What do you think?
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Old 06-23-2014, 09:21 PM   #70
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Re: RV There Yet? The tale of a 92 BB TC2000

It would be a good idea to do that but I opted to leave the existing and add more to my interior walls because I wanted to maintain a thermal break. I popped a few panels in several places and it all looked good. Riveted it back and carried on with the plan. My inside walls went up this weekend and I gathered more wood for the beds and all.
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