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Old 03-30-2010, 12:14 PM   #21
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Re: Rutgers tailgating bus

Ok, a question fellas. I got the windows out no problem. However, I realized that I will need either; 1. an air chisel to annihilate the rivets on the outside to get the flanges off 2. A heck of a lot of patience to slowly drill out each rivet and then try to punch it out with a pin punch.

For those of you who removed your rivets and then drilled pilot holes...How long did it take you to remove all the rivets necessary on each window and did you use metal drill bits? I'd like to know exactly what you used to get the stuff out and how long. I just want to remove the rivets and then rip off the flanges, scrape the excess glue off and then glue the sheet metal back to the metal with liquid nails and drill the sheet metal screws into the metal. I'd have to pre-drill before I guess. I can rip the windows out in a minute, but the drilling is what is stopping me right now. We're in a stone cold torrential down pour in NJ right now, but I think the sheet metal is okay for now since it's stuck under the lip of the metal over hang and then taped inside and outside around the seams.
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Old 03-30-2010, 01:07 PM   #22
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Re: Rutgers tailgating bus

Oh the rivets - they are a pain. I tried everything, air chisel and drilling (even with a special airplane tool), but I found the easiest for me was to grind the head off with a 4" grinder then clear the hole out with a punch or nail set. At first I thought I would be damaging the metal skin, but the head pops off before the grinder gets that far down. After the first two hundred rivets or so, I could remove one in about 30 seconds. Best of luck, and let us know what works for you.
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Old 03-30-2010, 02:22 PM   #23
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Re: Rutgers tailgating bus

Yeah, that's how I got 4 out last night. The only thing was I cut into the metal a little bit, obviously I can fix that with bondo but it seemed a little dangerous to me. I guess I can always do that as a last resort. I was trying to slice them off from the side. I guess I will try to remove them while trying to limit the damage. I will post pics of how it went when I am finished in a week or two.
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Old 03-30-2010, 03:34 PM   #24
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Re: Rutgers tailgating bus

I used a Zirconia Flap Disc wheel and set it right on top of the head of the rivit. The head pops off before getting to the metal and if not, because of the position of the grinder, the worst is taking the paint off. I didn't have any gouges. You can probably do the whole bus with two discs.
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Old 03-30-2010, 03:36 PM   #25
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Re: Rutgers tailgating bus

Quote:
Originally Posted by Wildcat
I used a Zirconia Flap Disc ...

Those things last forever and are worth their weight in gold when it comes to grinding down welds, rivets, etc...
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Old 03-30-2010, 10:11 PM   #26
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Re: Rutgers tailgating bus

RU
I bought some aerospace drill bits they are piloted bits or a step bit. used one larger than the rivet hole. Drilled the center out and the head just popped off.
e-bay Item number: 380140488225 Hope this helps worked for me.. Robert
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Old 04-08-2010, 06:42 PM   #27
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Re: Rutgers tailgating bus

We're not done yet, but I can't hold back the pictures I have.

We pryed the windows out with a crowbar. Some windows have a little old caulk or rubber sealant as you can see in the picture, but we lowered them halfway, stuck the crowbar in the sides and then wiggled them out.


Here is an example of us cutting off those pesky rivets!


You can see the old holes from where the rivets used to be. You can also see that we used liquid nails on the outside frames to secure the sheet metal more and to reduce rattling.


Sorry for the blur - a few wires popped out of the emergency exit windows. We cut them, capped them and wrapped them in black electrical tape.


We used some old scrap wood that I found at the curbs on garbage night. They will help give the sheet metal more support.


We pre-drill holes both outside and inside with titanium gold drill bits (4 broke so far and yes, we've been using oil to lubricate them). This is a shot of us drill in the sheet metal screws.


This side is finished.


We have one more sheet to cover on this side. The next two windows will be covered and then we'll be done.


Ta-da! Outside metal skins are completed. Time to build!
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Old 04-08-2010, 10:01 PM   #28
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Re: Rutgers tailgating bus

looking good!
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Old 04-22-2010, 05:26 PM   #29
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Re: Rutgers tailgating bus

We have now cut and fit the furring strips/insulation and covered the walls with luan plywood.

Window insulation fits pretty snug.


We set strips 16" apart so the walls would have support. I also started using left-over red rosin paper but it was ticking me off so I ripped some of it off and didn't apply anymore. Make sure you pre-drill the holes first and then drill in sheet metal screws. We had an air drill that made it fun, but it's no picnic with a regular drill.


First wall up. We opted not to insulate by the heater. I am worried of a potential fire hazard, but the heater will eventually be surrounded by air vents. Also the bottom 6" of the floor wasn't covered because it will be covered by benches anyway.


Wall in the back is up. I started gluing cardboard beer signs on the side and back as a border.


We wanted it to look good on the passengers side, and this metal lip that attaches to the original seats was a hinderance. We used an air compressed angle grinder this time. It took some time but we cut what we needed.


Tightly framed and insulated. Strips were put in place every 16" (not shown).


Looks clean.
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Old 04-27-2010, 09:59 AM   #30
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Re: Rutgers tailgating bus

I'm excited to start working on our bunk beds today. My buddy and I are both stubborn on building materials and how to do certain things, but as you guys can see from the pictures, progress is coming along nicely. I hope to have the bunks done by the end of the week. It's just funny though, because you always run into small problems that you didn't forsee beforehand. I'm sure we'll run into some while working on the bunks. I wanted the beds 30" wide, he wanted them 24" wide, we might have a wrestle off in home depot, because no way in hell can I fit on a bed that's 2 feet wide, and some of my friends are larger than me lol. So if anyone sees two guys wrestling in the lumber section...just give me my 2 points when I have him in a headlock lol.
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