Removing safety lights

[Zizzer]

I am required to disable/remove the front and rear safety lights from my bus. These are the large lights above the windshield and above the rear door that come on when the stop sign opens.

Removing the lights has proved simple enough. Constructing a cover for the holes from sheet metal was simple enough and attaching it will require just a handful of screws.

My problem is that I'm not sure what I can use to seal the space between the body and the sheet metal cover. Caulk of some sort? Is there tape or putty that you can use?

The other question is whether I need to do anything with the wire ends still inside the bus? Can I just leave them? Remove the fuse for that system? Tape the bare wire ends?

Thanks

[PNW_Steve]

I have used 3M 5200 marine adhesive/sealant on similar projects with very good result:

3M 5200 10 oz. Marine Adhesive/Sealant-PN06500HC - The Home Depot

As always, good surface prep is very important.

[Zizzer]

Originally Posted by PNW_Steve

I have used 3M 5200 marine adhesive/sealant on similar projects with very good result:

3M 5200 10 oz. Marine Adhesive/Sealant-PN06500HC - The Home Depot

As always, good surface prep is very important.

So ... I ... uh ... called 3M. I read reviews and questions sections in ads and 3M had replied asking that people call them, so I did.

A human picked up the phone in about a minute and answered all of my questions and referred me to another similar product that they recommend for exterior use because it has some sort of UV protection that the other does not. It is a whooping $.12 more! The bastards and their bate and switch.

https://www.amazon.com/gp/product/B0...=AP9TLT2LX6QXY

Prep looks simple enough. Clean with soap and water, buff with fine grit sand paper, wipe with "solvent" (I'll be using denatured alcohol), set a bead and screw the cover in place.

Is there a way to seal or store the tube for future use?

[DoubleO7]

find a mobile home or rv supply store and get a roll of thin butyl tape.
Should be no more than $5 for a roll that is 3/8 to 1/2" wide and 100ft long.
Clean surfaces of dirt and oils stick tape on back of cover and screw down.

Using 5200 or even the 4000...you will never get it off once cured. And paint won't like where ever it was.

[DoubleO7]

Originally Posted by Zizzer

Is there a way to seal or store the tube for future use?

have a vacuum (bag) sealer?

[Iceni John]

Once you open a tube of 5200 you need to use it all, or it will harden. I used it to attach a single piece of aluminum across the front of my entire front cap when I covered my front flashers, much neater looking than riveting on individual covers over each light. When it's all painted body color it will look like it came from the factory that way. 5200 takes up to a week to completely cure, so you need to secure whatever you're bonding to prevent it moving during that time.

It's not silicone-based (it's a polyurethane-based product), so would it affect paint adhesion?

John

[Tango]

RE; the use of alcohol...

Be sure to check the directions as quite a few sealers and adhesives are NOT compatible with alcohol. I would think as long as it was fully dried, it would be fine, but a number of them state that using alcohol to "dress" the finish will prevent setting.

Just one more thing to keep in mind.

[Lowkee]

I personally prefer Sikaflex 221 or 3M Automotive Urethane Seam Sealer