Floor Replacement

[New2Skool]

Posting pics here still doesn't work and I got a private msg about using this method but its not working so.

Imgur: The most awesome images on the Internet
Imgur: The most awesome images on the Internet
Imgur: The most awesome images on the Internet
Imgur: The most awesome images on the Internet
Imgur: The most awesome images on the Internet

[EastCoastCB]

just copy the image address by right clicking on the image, then paste it in the message body using the image tool in the toolbar.

Or maybe it just isn't working for you.





is that a Vaughan pry bar?

[New2Skool]

I tried to post and link the image with the picture attach button.
It just posted dead links.

I will try the copy and paste the next go round.
Thank you, I will get it eventually.
I refuse to spend more time streamlining this site than researching my bus hahaha.

I have no idea what kind of pry bar it is.
I call it old blue.

[EastCoastCB]

Originally Posted by New2Skool

I tried to post and link the image with the picture attach button.
It just posted dead links.

I will try the copy and paste the next go round.
Thank you, I will get it eventually.
I refuse to spend more time streamlining this site than researching my bus hahaha.

I have no idea what kind of pry bar it is.
I call it old blue.

I've never had any issues using Imgur or any pics from the web.

[New2Skool]

Ok, that you buddy.

So, what do you think of my mess?

[Robin97396]

You build things strong. That's pretty cool. I feel bad about all your rust and how it's complicated your build but you're always powering through it. You take good pics too.
No, I didn't think you were asking me. Just my few cents worth.

[New2Skool]

Oh no Robin,
You are always welcome to comment and make suggestions.
I value your input and everyone's input.
It is my project, gets my mind off of everything and I need that mental break from time to time.

[EastCoastCB]

Originally Posted by New2Skool

Ok, that you buddy.

So, what do you think of my mess?

YOu got a project for sure man! I think you can save it though.

Its great to see you tear into it so thoroughly.

[cadillackid]

Originally Posted by New2Skool

gets my mind off of everything and I need that mental break from time to time.

precisely one reason i bought a bus! I work so much that I need a distraction.. something to build..

I think you got this project on the run... now that you know what to do you can execute..

-Christopher

[Robin97396]

Cool but my experience with buses is limited to the buses I own, other than what I've learned on this site. I could have made better choices myself but then I didn't have all that bad of luck. I did end up with the 545, but the undercarriage of this bus still has some of the factory writing showing. I hope that cleanliness helps when I get to insulating down there.
I like your project because it's a lot of fabricating through this point. I feel bad for you, but you do a good job and take such good pics. Something I can relate to. Still, don't know beans about skinning buses and lots of other things. Like you've been doing, it's generally common sense. You do a more thorough job on things than I would a lot of times. Good to see.

[New2Skool]

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

[EastCoastCB]

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!

[Docsgsxr]

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"!

[New2Skool]

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.

[New2Skool]

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?

[Robin97396]

That's just in that localized area where the Z rust was on the wheel well?

[New2Skool]

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.

[New2Skool]

By the way, thank you guys for teaching me how to properly post pictures here.

[New2Skool]

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

[Robin97396]

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.