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Old 12-07-2016, 12:00 AM   #1
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Newbie with a Shuttle Bus

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We have a 92 E350 24ft shuttle conversion by champion. We can't wait to dive into this forum with some seasoned minds.

Our current project is picking out the flooring and insulation. I was thinking insulated vapor barrier with floating floor that will be fastened with benches.
And possibly insulating the exterior floor.

Still in contemplation, so many questions.
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Old 12-07-2016, 06:03 AM   #2
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Poke around your wheel arches. My Champion had all kinds of rust. The factory Ford wheel arches didn't match up with curvature of the Champ body-missing by about 3 " . They filled in the whole gap with expandable foam-which collected water over time. I ended up having to scape the foam out + replace some metal. If you see any rust on the outside metal below the beltline around the wheels, the problem started inside around the arches.
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Old 12-07-2016, 03:30 PM   #3
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I have an E-450 shuttle bus. The biggest pain in my ass has been screwing anything into the fiberglass walls and keeping it there. I definitely recommend removing them.

-Thomas
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Old 12-07-2016, 07:52 PM   #4
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Hello from West of the Mississippi.
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Old 12-07-2016, 07:55 PM   #5
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Welcome, glad you are here!
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Old 12-09-2016, 10:58 AM   #6
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Quote:
Originally Posted by sdwarf36 View Post
Poke around your wheel arches. My Champion had all kinds of rust. The factory Ford wheel arches didn't match up with curvature of the Champ body-missing by about 3 " . They filled in the whole gap with expandable foam-which collected water over time. I ended up having to scape the foam out + replace some metal. If you see any rust on the outside metal below the beltline around the wheels, the problem started inside around the arches.
Oh boy, they sure used a lot of spray foam on these units. I had a look under those wheel wells, and from what I can see no rust, just a lot of road build up; seems to have given the foam a protective barrier. For now, I will leave it. Especially since my current climate is too humid to properly replace it... But trust me, I have removed a copious amounts of rust from the roof, pretty much replaced all the seals up there and put on a new skin. Oi, chasing rust is like chasing condensation.
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Old 12-09-2016, 04:15 PM   #7
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Chassis: Ford e-450
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Originally Posted by KevlarGypsy View Post
Oh boy, they sure used a lot of spray foam on these units. I had a look under those wheel wells, and from what I can see no rust, just a lot of road build up; seems to have given the foam a protective barrier. For now, I will leave it. Especially since my current climate is too humid to properly replace it... But trust me, I have removed a copious amounts of rust from the roof, pretty much replaced all the seals up there and put on a new skin. Oi, chasing rust is like chasing condensation.
The tell is the aluminum trim holding down the carpet near the arches. If it is crusty, you have rust there. Also below the rub strip on the outside. (If your box is like mine, its glass from the floorboards up-thin steel from the rub strip down.)

http://www.skoolie.net/forums/f27/a-...ild-13860.html
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Old 12-10-2016, 08:04 PM   #8
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I have an E-450 shuttle bus. The biggest pain in my ass has been screwing anything into the fiberglass walls and keeping it there. I definitely recommend removing them.

-Thomas
Hi Thomas, so did you end up removing the walls? If so how did you deal with the rivets?
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Old 12-10-2016, 10:54 PM   #9
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Hi Thomas, so did you end up removing the walls? If so how did you deal with the rivets?
No, unfortunately I found this site for knowledge after I had gone too far. My build is almost finished. In order to hang overhead metal cabinets I ended up bolting them all the way through the outer wall. Kind of looks like it has a couple rows of piercings from the outside. My next bus I will fully insulate.

-Thomas
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Old 12-11-2016, 02:30 PM   #10
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Ok Thanks! Hope you post some photos of your end result!
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