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Old 05-24-2016, 07:15 AM   #91
Skoolie
 
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Location: Bemidji MN
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Year: 1998
Coachwork: Carpenter Body
Chassis: International 3800
Engine: DT466
Rated Cap: 65 to Zero. Folding Chair
Post Leaks

When, I first ripped into my bus I noticed a few leaks along the walls.
I removed the molded insulation, the windows which had a very good thick black tar like sealant around the bottom.
Some of the rivets from the exterior skin into the interior side were rusted and formed drops when it sprinkled.
I thought that was normal, especially around the windows since I removed that heavy tar sealant.
Little did I know that the leaks were not from the windows or condensation from the rivets.
The leaks were coming from behind the rub rails where the exterior skin was so rusted and destroyed water was freely flowing into the bus and walls.
In a few long spots behind the rub rails the only thing holding the skin together was the paint.
Heartbroken, I had to face the possibility of replacing the entire outer skin.
After a few questions here, I decided to do the replacement.
This tied in with the lift, I would use two sheets of sheet metal to replace the outer skin.
I am comfortable in the newly designed repairs and project.
The only issues I have are;
The work involved, the mass removal of support structure (Interior & Exterior walls) and the timing to link in rust removal.
Soon enough my bus will have a covered wagon appearance, a flat bed with ribs supporting an intact roof.
I will use this opportunity to hit rust removal very hard.
I will sneak my bus into work where the maintenance guys will let me use the heavy duty trailer mounted gas powered, power washer to blast rust from the floor, undercarriage and anything else it may need.
Once, that is completely the fine detail work and prep begins.
Followed by priming the surfaces with an oil based metal primer that I bought from Menards.
I am nervous around ripping the bus down to the bare floor and wall frame work but, it gives me a great opportunity to address any rib rust, floor rust and access to the undercarriage.

If anyone has suggestions or comments before all of this starts happening, please let me know.
Thanks.
Del
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Old 05-24-2016, 07:31 AM   #92
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Coach guys have to do this kind of extensive work a lot, too man.
Check out some of the more extensive builds and you'll see what I mean.
Post up as many pics as you can along the way!
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Old 05-24-2016, 07:38 AM   #93
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You do have some work ahead of you, but when you're finished, you will know every single detail about your skoolie! Excellent way to "show us up"!
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Old 05-24-2016, 10:52 AM   #94
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Eastcoast, I checked them out and I am glad it has been done before. Good examples of how and the finished product.

Doc, yes I'll document everything.
I'm nervous about the structure and driving it five miles to work to power wash it.

I'm excited about doing it.
A new fresh canvas to start my little personal masterpiece.
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Old 05-24-2016, 07:20 PM   #95
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Question Rib Reveal Surprise

Well, get a load of this.
The ribs are not directly attached to the floor of the bus.
The ribs are riveted to the lower interior wall / seat rail section which is attacked to the floor lightly with screws.
I was shocked to rip the outer skin off and find about 1/16-1/8th of an inch between the bottom of the rib and floor of the bus.

I pictured some sort of bracket, or socket that held the ribs in place.
Plus a ton of rust flakes inside of the former wall cavities.
Check out the pictures.







Now, what I plan to do is continue removing the skin. Once it is exposed completely, I will clean up the areas immediately around the ribs. Weld small L brackets from the ribs to the floor to add some structural support.

Once, I have brought my naked bus to work and blasted the rust off with the gas power washer. I will return and wire wheel target areas and add a horizontal support beam between each rib to give the replacement skin surface area to mount too in accordance with the lift measurements.

So, basically I plan to create boxes using the ribs and the new mid beam to help support the structure and mounting of the new skin. Compartmentalizing my support structure.

I was very surprised to see the lack of contact between the ribs and the floor.

What do you guys think?
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Old 05-24-2016, 09:01 PM   #96
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That's just in that localized area where the Z rust was on the wheel well?
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Old 05-24-2016, 09:22 PM   #97
Skoolie
 
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Robin,
Nope that section is the very rear driver side panel and rib.
The ribs above the wheel wells is not attached to anything.
The rib above the wheel well ends at what would have been the top of the wheel well.
It had no structural support from the rib to the floor or chassis.

Here is a picture of the wheel well rib.
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Old 05-24-2016, 09:24 PM   #98
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Picture Posting

By the way, thank you guys for teaching me how to properly post pictures here.
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Old 05-28-2016, 04:32 PM   #99
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Location: Bemidji MN
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Year: 1998
Coachwork: Carpenter Body
Chassis: International 3800
Engine: DT466
Rated Cap: 65 to Zero. Folding Chair
Cool Skinless, Boneless Bus

Hello Gents

Over the last week, I have removed the skin of my bus.
Here are some more pictures.
If you have any suggestions or questions feel free to ask.
Thanks,
DLJIII







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Old 05-28-2016, 08:00 PM   #100
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Sorry about the pictures. Sometimes it works and sometimes it works temporarily and sometimes it just don't work. It could have something to do with the time of day you're trying to upload. To many variables. Sometimes it works.
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