I knocked off at 2 today and played with the bus some more.
To get the roof buttoned up, I need to figure out the air conditioner. I pulled the A/C unit out of the garage and did a little hot wiring. Other than a sticking contactor, it fired up and cooled fine.
There are a couple of problems though.
First off, I think it looks like crap. A big ugly white box on the roof pretty much screws up the lines of the entire bus. It will probably look better on a white roof, but I still don't like it.
The other problem is the inside shroud is huge, designed for a flat surface, and the cabinet doors hit it. It hangs down 2+ inches I can't afford to lose. My son, pictured below is 5'10", I'm 6'2". It's not going to work.
So, my choices are to scrap what I have and find something different, basement air mounted under the bus or a low profile ducted roof mount. Hack up what I have and build something different, mount it under the bus and build ducting to reroute the air. Or modify what I have to work for now, understanding that it is probably a short term (1-2 year) fix.
Funds being a little short for now, I'm going to go with option 3. Even though I don't really like the looks, the unit is going to mount on the roof. I don't have to modify the roof to install it and I can pull it later and install a regular vent. I'll have to build something less obtrusive for the interior. The roof is 2" thick, I think I can fab some vents that will fit up in the roof and then relocate the controls to one of the cabinets.
More to come on that.