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Old 06-18-2018, 04:09 PM   #1
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Join Date: Mar 2018
Posts: 2
Shuttle bus roof (sealing emergency hatch?)

Hey! First post, but I have been reading and lurking for quite sometime. We recently picked up 2008 Chevy C4500 Goshen shuttle bus and are in the midst of the demo and was hoping for some guidance as I am planning some pieces...

Anybody have any recommendations for the best course of action to seal the hole of an emergency exit hatch? The existing emergency exit is leaking significantly (between the bus/hatch join, not the mechanicals of the hatch itself) and so I am thinking the best course is just going to be to remove the hatch and close the hole.

I am fast approaching the ceiling demo (walls and floor nearly done) and have been leaving this one as I need a strategy to deal with the giant hole/not entirely certain what my best materials choice will be. I would just replace the hatch but don`t really care to spend the couple hundred bucks for a new one and all of the anecdotal info I have suggests they all leak anyways. I am open to any other thoughts or options!
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Old 06-18-2018, 04:30 PM   #2
Join Date: Jun 2018
Location: Pacific NW
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Piece of sheet metal cut about 1.5" oversize.

Drill for rivets, butyl tape, rivet it down and seal the seams.
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Old 02-07-2019, 03:18 AM   #3
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26 inch semi-domed skylights (clear, smoke or white/opaque) on amazon (brand: ICON) are looking appealing to me if I don’t make the hole smaller to mount a maxxair fan. About 100$ for skylight.
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Old 02-09-2019, 10:50 AM   #4
Join Date: Feb 2019
Location: Kansas City
Posts: 15
I just retired from doing commercial roofing after 35 years. Go to your local roofing supply company. Ask for a product . Heck here is a link
H.E.R. | Hot Roofs. Cool Solutions.

This is the only product I would use on a build. It is great. I have only used the buckets and sausage rolls.
If you get the sausage roll. Just cut a hole in the end and squeeze. FYI rubbing alcohol for clean up.
And use frog tape to outline your work

Wear gloves and use a brush.
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Old 02-11-2019, 05:46 PM   #5
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Location: Dawsonville, Ga.
Posts: 4,245
Year: 1999
Coachwork: Genesis
Chassis: International
Engine: DT466/3060
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I went a step further than a sheet of metal. I figured why not utilize this space to bring light into the bus. On the rear hatch I secure with butyl tape and screws a 26" piece of tinted Lexan. I then mounted the 14" vent fan in the center of it. I then replaced the front hatch with just the 26" tinted Lexan, huge light coming through that one.
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Old 02-17-2019, 12:04 PM   #6
Join Date: Aug 2017
Posts: 29

Hereís what I did. Itís a $20 doggy dome off amazon.
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Old 02-17-2019, 01:31 PM   #7
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Join Date: May 2016
Location: Illinois
Posts: 444
Year: 1996
Coachwork: Amtran
Chassis: International
Engine: DT466
Rated Cap: 65
Originally Posted by Tstege View Post
Hereís what I did. Itís a $20 doggy dome off amazon.
Brilliant, perfect for stargazing too!
Our Build:
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Old 02-19-2019, 12:07 PM   #8
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Location: SW New Hampshire
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Or shooting a fix off the North Star with your sextant, if that's how you're navigating.
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