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Old 08-05-2013, 05:58 PM   #1
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Ugh, the not square Thomas buses.

If you plan to raise your roof, get a Bluebird. Thomas buses are not square.

The first issue I had was the fact that the windows lean in about an inch.



After I raise the roof 10" the post will not line up.

Some people smarter than me said this is easy to take care of. I just have to cut the top post on the left side and move it left. Cut the bottom post on the right side and move it right until they line back up. Then weld where you cut. Repeat for me 22 times. I'm only raising from the first to the 11th window.

Now I need help from those smart people. Unlike a Bluebird my post are not square tubing. It is U channel, and it is not square.



Any ideas on how to re- attach? I was going to use 1 1/4" square tubing until I found out it is not square. I want to put a piece in from the top to the bottom of the window area and weld to the existing.
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Old 08-05-2013, 06:58 PM   #2
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Re: Ugh, the not square Thomas buses.

I can understand raising the roof if you are too tall to walk in it comfortably. Consider, however, that you will be sitting in your bus 90% of the time.

Someday, I may "raise" my roof. My approach will be different.

I will cut an access hole in the roof. I will weld the top half of a full size van to the bus. I will then make the van addition into a bedroom.
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Old 08-05-2013, 07:03 PM   #3
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Re: Ugh, the not square Thomas buses.

Once I re-insulate my interior height will be 6' and I'm 6' tall. I want a little head room. I always where a ball cap and rubbing that buton on the top into my head does not sound like fun
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Old 08-05-2013, 07:29 PM   #4
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Re: Ugh, the not square Thomas buses.

You could always just learn how to slouch.... I'm sure with a bit of practice you could easily gain 2 inches of headroom that way!

Or You could insulate the floor from the bottom... and leave that inch or so on top.
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Old 08-05-2013, 07:50 PM   #5
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Re: Ugh, the not square Thomas buses.

Use round tubing, .083 wall (14 ga) easy to weld no blow thru(like thin and it will "pull everything into a comfort zone...you can only weld what you can see!
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Old 08-05-2013, 07:56 PM   #6
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Re: Ugh, the not square Thomas buses.

Make the 1-1/8 dia pcs (do not use DOM too much $$) about 23-7/8 long this will allow saw cut and plenty of strength

If you need help pm me and I will call at work and hook you up to possible sources.

So a 24 foot stick will give you 12 pcs

Cut roof the same way top to bottom toallow angle change when you clamp the 1-1/8 in it will align it mostly
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Old 08-05-2013, 07:58 PM   #7
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Re: Ugh, the not square Thomas buses.

When I first stared to research living in a school bus, head room was something I was concerned about. When I found this article:http://www.gumpydog.com/Bus/MC9_WIP/...g_the_roof.htm

Lights went off. If he could raise the roof of a MC9 transit bus. A school bus should not be any more difficult. Then I read:
The Millicent Chronicles; two foot roof raise, big tailgate

Now I want to do this. No turning back.
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Old 08-05-2013, 08:00 PM   #8
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Re: Ugh, the not square Thomas buses.

Round tubing is stronger than sq or rect. Same size,going with 1/8 is way overkill....it is just so easy to weld with longer duty cycle welders except dynasty series millers...they are "bible banging"
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Old 08-05-2013, 08:00 PM   #9
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Re: Ugh, the not square Thomas buses.

Quote:
Originally Posted by bansil
Make the 1-1/8 dia pcs (do not use DOM too much $$) about 23-7/8 long this will allow saw cut and plenty of strength

If you need help pm me and I will call at work and hook you up to possible sources.

So a 24 foot stick will give you 12 pcs

Cut roof the same way top to bottom toallow angle change when you clamp the 1-1/8 in it will align it mostly
You told me on my post about using round tubing, I guess it did not sink in. Thanks.
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Old 08-06-2013, 07:42 AM   #10
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Re: Ugh, the not square Thomas buses.

How much welding do you do? If your good enough you would just get the smaller size square tubing, 1-1/8 I think It was. So 1-1/8 square tubing and just fill the gap where it widens to 1-1/4. i have done wider than that, i eyeball a lot of stuff i make and have to most of the time. Would be very easy, and would help if you cut one all beam piece out and used it for a test weld, then just use more square tubing to fill the length you cut.
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