Dropped a bunch o' plans off at the local sheet metal shop along with my door frame. Hope they can skin it without too much distortion. The danged frame had to be straight down the leading edge and have a couple of inward curves on the back edge...that's how the "hole" is. Having it made with a 3/4" lip over the bottom & rear closing sides, the top will have a rubber weather flap. The other stuff consisted of a pair of covers to block out two windows, a box to cover the fuel fill where it comes through the wall and down through the floor and, a great big oddly shaped box that will house the A/C in the rear of the roof. It will also do double duty as the base for that part of the roof deck. Here's a couple of pix...
Big hole in the roof (picture an A/C here eventually). Note that the spacing between the inner & outer roof is not constant. Will likely make fabbing reinforcement for this area a real PITA.
Not quite as big a hole as Jack's, but kinda scary just the same.
Seems like all I'm doing these days is making big holes where stuff used to be...like an engine & tranny.
And...a note regarding paint choices.
In the process of working on this old girl, I discovered that someone, at some time, had either stripped or sandblasted most of the original paint off and re-painted it with latex house paint directly onto bare metal. Mostly down the sides but part way up the roof as well. While sanding I noticed that anywhere there was only the the badly peeling latex, the metal was rusty and pitted pretty badly in places. Nothing through the metal (as yet) but definitely a huge difference between those areas and the ones that still had some of the original school bus orange (they weren't yellow back then) underneath the latex. Those areas were clean and pit free even after 66 years. I have to conclude that the latex is a pretty horrible choice over metal. I felt obligated to pass this along since I've noticed a fair amount of folks going the latex route with their buses. Over existing paint it seems to be OK if less than perfect, but over bare metal...a really