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Old 04-23-2013, 09:40 PM   #241
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Re: The Camel Conversion Project

I added an edit to my post from earlier today.
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Old 04-25-2013, 12:35 PM   #242
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Re: The Camel Conversion Project

Thanks PDB. we're planning on using the spray on liner stuff only where the foam would be exposed to the elements below. With under the floor insulation I'm still wondering - spray the whole underfloor, then mount belly boxes and such and insulate the boxes, or just mount the boxes and spray everything? The balance between wanting to go over kill on everything and save money is driving me nuts!
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Old 04-25-2013, 04:41 PM   #243
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Re: The Camel Conversion Project

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Originally Posted by inkblots84
Thanks PDB. we're planning on using the spray on liner stuff only where the foam would be exposed to the elements below. With under the floor insulation I'm still wondering - spray the whole underfloor, then mount belly boxes and such and insulate the boxes, or just mount the boxes and spray everything? The balance between wanting to go over kill on everything and save money is driving me nuts!
Unless you have a legitimate reason for insulating the belly boxes, I would avoid it. This stuff is expensive and you should try to use only where you absolutely need to. Since I was using rigid styrofoam to fill in between the wall studs, I could get away with a single foam kit. If I were to start with bare walls and expect to get three inches of insulation, it would have taken at least two kits, but no more than three. Of course, I'm only using the front half of the bus for living space. Anyone converting an entire 11-window school bus will need a lot more. In that case, I'd be tempted to go with a professional installer and see what that would cost.
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Old 04-25-2013, 11:11 PM   #244
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Re: The Camel Conversion Project

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Originally Posted by Part-time
I had a few quotes to do the underside of my floor sprayed, roughly 33'x8' so 264 square feet at 3" thick. They all ranged between $400 and $800.
I am going to get mine done sometime within the next couple of weeks, when the guy is available... at $400 I'll be flexible to his scedual
I'm building my belly boxes after and if I figure any need insulating I will use 1" styrofoam.
That's a good price. The Foam It 602 kit covers approx. 600 sq ft one-inch thick, so what you're planning is roughly equivalent and for that price, you can let someone else do the dirty work (the kits cost about $750 with the HAZMAT shipping fees). And it is dirty work, believe me.

The biggest drawback to having it done by someone else is making sure you know (in writing) before they start just exactly what the finished product will look like. You may have to demand it be done again if they somehow screw it up or only cover two inches thick or whatever. If it's not in writing, they can always say, "Hey, that's what we told you it was going to be," and you'll have no legal recourse.
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Old 04-25-2013, 11:31 PM   #245
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Re: The Camel Conversion Project

Picked up one of these today: Stanley FatMax Reversible Flush Cut Saw, $12 at my local Lowe's (though not listed on their website). It's perfect for cutting off the foam squeeze-out by the studs. I tried it out tonight before it got too dark to work and will finish tomorrow, but I can tell already that it's just what you'll need for trimming the foam, and much cheaper than a dedicated electric foam saw. The reversible feature is great for getting into corners of all angles, too.

Still makes a helluva mess, though. I'll be vacuuming more styrofoam beads and foam dust tomorrow.
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Old 04-26-2013, 08:10 PM   #246
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Re: The Camel Conversion Project

So I finished trimming all the squeeze-out and it wasn't that bad. The saw I used was great for knocking down the large chunks, but the bed platform was a special case that required a special tool. Since my bed is going to be on this surface, I want it to be as flat as possible. Any insulation between the platform joists needs to be no higher than those joists to avoid hills in the plywood that will be laid on top of them. I used a random orbital sander (with a vacuum attachment) to flatten the uneven surface and it worked like a champ. It's not as fast as the saw, but it does a much finer job of removing small amounts of foam. And with the vacuum attached, it's also much cleaner than the saw. Finished results:



The hand saw leaves a rough cut:


The sander leaves a very smooth surface:


Bed platform foam finished:
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Old 04-26-2013, 08:53 PM   #247
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Re: The Camel Conversion Project

Almost forgot about this. The other day I cut and mounted a plywood cover for the box over the driver's head. My DC and AC control panels are in this area, so the cover only hides all the wiring.

Since the rest of the bus is going to be very efficient and straightforward, I wanted to add a bit of whimsy to this one spot. I first mounted the uncut board and installed all the screws in their final positions. Then I took the whole thing down and cut the lines for the center removable panel. When I reinstalled the three panels and reused the pre-positioned screw holes, everything lined up exactly with only a blade-kerf gap between the panels.

The middle panel will be screwed only at the bottom edge and will slide into a slot formed by the ceiling and the structure in front of the panel. I'll need to get in here in case I want to work on the 12VDC or 120VAC wiring.

In retrospect, I probably should have cut the lines in a thicker-in-the-middle pattern, but this is reminiscent of the curves of a woman's body, so I'm going with what I've got.

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Old 04-29-2013, 09:09 PM   #248
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Re: The Camel Conversion Project

Just a small update to show my installed 1/2" plywood bed platform. It's very flat.

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Old 04-30-2013, 07:59 AM   #249
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Re: The Camel Conversion Project

SO............when are we going under surgery?.I wanna see the jeep in there
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Old 04-30-2013, 08:05 AM   #250
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Re: The Camel Conversion Project

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SO............when are we going under surgery?.I wanna see the jeep in there
Soon enough it will be. Patience you must have.
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