My new job started this week, midnight to 8am, so not much to report. I will be taking out all of the windows, including the exterior pillar covers, in order to fit sheet metal in so I can get the inside ready for primer. I've been avoiding doing the metalwork at the floor in the front. I need at least 2 reasons to go to the metal shop, and I should have those reasons by the end of the weekend.
On an interesting note, when I pulled the first pillar cover off, I saw this:
I never knew there was insulation inside
the ribs. This piece goes all the way to the floor and I can see the end of a piece that goes into the ceiling arch. Hmmmmm. Maybe this would explain some frustration with using Great Stuff spray foam on my buddy's bus to fill the ribs.
So, I was thinking about covering the windows with sheetmetal that would be bent into a shallow sawtooth pattern, repeating every window width. It could only come out from the surface of the bus by about an inch and still be protected by the drip rail. I thought the effect would look pretty cool (visions of the "Nautilus" from 20,000 Leagues Under the Sea) but after making a quick rendering in my design program, I decided against it.
It would be too much work and too much extra cost for materials to be worth what little of an effect it would have. Also, there would be the problem of making it seal properly without removing the entire upper skin of the bus, not to mention how out of place a window would look. I will have to find some other avenue of artistic expression.
I will be screwing the sheet metal panels (overlapped from back to front starting at the rear of the bus) into the ribs at an interval of 1-2 inches between screws. I will, of course, need to put some kind of weather seal / bonding agent where metal meets metal. Recommendations?
Oh, and using a propane torch to try to burn the masking tape stuck to the inside of the bus is not recommended.