I got a bit of a chance to work on the bus this weekend. I had been spending time attempting to do better in school and got rather sick for a few days. It is very, very hard to concentrate on schoolwork with this project going on.
I have been working on this and that, experimenting with different projects. I bought a gallon of "OSPHO" rust treatment; basically stuff you brush on and it turns iron oxide (rust) into iron phosphate, which doesn't harm the metal (science!).
I took out all the side panels and insulation that I could get to. There is still a bit of insulation behind the thicker metal left by the floor. This metal has a ridge at the top that the seats bolted to, and I am planning on cutting this off because it will get in the way of my walls. I am leaving some of the metal, because it is structural, it appears. You can see a few of the holes I cut in the floor to isolate / remove any really heavily rotted / rust through areas.
Here is one of the sheet metal patches marked up and ready to cut.
Here is the hole in the floor it is going over (poor photo).
And here it is welded in.
Done with a Hobart 120 volt MIG welder with flux-core wire.
A few more patches...
And I have yet to do this one. It is a bit tricky. It's also fun having to do this by yourself and right after welding, throw off the mask and run under the bus and put out fires (burning undercoating).
I plan on sealing the seams from underneath and above with polyurethane seam sealer (automotive grade) once I am done with the patches.
Here is a test section of the OSPHO stuff. I quickly wire-brushed the area and just brushed it on. This is after about 10 minutes. I came back the next day and the rust had turned black, and it leaves somewhat of a coating on the surface. The stuff is $40 a gallon shipped on Amazon and is very strong, I highly reccommend it. I am going to do all the rusty floor areas with it once I am done patching. You just wire brush the loose rust off, paint the ospho on, and let it dry, then paint over the dried ospho.
Also, I picked up all these cabinets for free from an office being demoed.
They fit well in the bus.
Later this week and weekend I will be finishing up the patches and wirebrushing the whole floor, (rusty areas) vacuuming it, wire brushing again, vacuuming again, and laying down ospho liberally. Then to let it dry and paint with some metal primer, and seal up with seam sealer. Before I can start on insulation I need to seal the roof completely, which will mean fixing the hatches (temporarily?) and painting the roof with several coats of elastomeric coating. I also need to pop out all the windows, scrape the old sealant off them, and silicone them back in.