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Old 10-21-2015, 05:35 PM   #1
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Year: 1992
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Is this the end for me and my bus?

I went to my bus today to begin work on the ceiling. I figured because my bus had so many leaks that I should take care of those first before doing anything else. So I began to remove the spray foam and this is what I found underneath it all..

First look underneath. Super brittle awful rust right away. Not a good start.


After removing one whole panel. Whole thing is rusted. Terrible.


Full ceiling shot after removing several more panels of spray foam. I imagine the entire ceiling is like this.


Fist-sized hole accidentally but easily punched through with my hammer. So brittle.


More holes.


Shot of two of the ribs completely eaten through with rust. They're practically not even connected they're so tenuous.


Weird thing: everywhere there was spray foam there was rust underneath. Spots like these where there wasn't spray foam had no rust at all. This is where a speaker was.


This is where another speaker was.


I decided to chip away a side panel to see what it was like underneath and there was this stuff. A weird flaky wood-like substance with another layer of it underneath.


Closer shot. I didn't peel back the back layer. There's probably rust underneath.


This feels hopeless. What can I do about this without spending potentially thousands of dollars? A guy told me I could check out a scrap yard for a bus like mine and just completely replace the top but what's the likelihood that I'd actually find one that would fit perfectly? This is so awful. I hope I didn't just waste a whole bunch of money and time.
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Old 10-21-2015, 06:32 PM   #2
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Could you get some sheet metal to replace/patch over the parts that rusted through? Weld and seal with silicone? Someone with more experience could probably chime in, but that's my two cents.
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Old 10-21-2015, 06:49 PM   #3
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Man that's extreme.
What was the root cause of that amount of rot? Leaking roof not repaired or not repaired properly then foamed over?
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Old 10-21-2015, 06:53 PM   #4
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Quote:
Originally Posted by Brie View Post
Could you get some sheet metal to replace/patch over the parts that rusted through? Weld and seal with silicone? Someone with more experience could probably chime in, but that's my two cents.
There's structural rot there, some of the ribs are GONE.

Whats your level of fabrication experience, Moopy?
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Old 10-21-2015, 07:03 PM   #5
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That sucks. Wish i could help.
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Old 10-21-2015, 07:07 PM   #6
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Quote:
Originally Posted by EastCoastCB View Post
Man that's extreme.
What was the root cause of that amount of rot? Leaking roof not repaired or not repaired properly then foamed over?
I couldn't tell you though I noticed this as I was examining it.



Seems to be a non-rusted piece of sheet metal over top the rusted one, like a half-assed patch job or something. You can see it in better context here:



Also if you notice there's like pine straw and $hit between the bars and the ceiling. I have no idea wtf happened to this roof.


Quote:
Originally Posted by EastCoastCB View Post
There's structural rot there, some of the ribs are GONE.

Whats your level of fabrication experience, Moopy?
Zero.
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Old 10-21-2015, 07:22 PM   #7
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Was the foam in place when you bought it or did you have it applied? It is pretty obvious that there was an intense reaction between whatever the foam is and the metal. I'm just guessing, but was it was galvanized?

That is some seriously serious oxidation. So sorry man.
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Old 10-21-2015, 07:26 PM   #8
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Was the foam in place when you bought it or did you have it applied? It is pretty obvious that there was an intense reaction between whatever the foam is and the metal. I'm just guessing, but was it was galvanized?

That is some seriously serious oxidation. So sorry man.
It was in place when I bought the bus. There's also spray foam UNDERNEATH the entire bus. I am praying all of that doesn't look the same as all of this. This is some seriously awful $hit.

I have no idea if it was galvanized or not.
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Old 10-21-2015, 07:40 PM   #9
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Whatever was sprayed by whomever...it obviously was never meant to go over metal. It looks like someone sprayed hi-powered acid on it. Real bummer.

Just thought of something...if I remember correctly...that reaction is exactly what you get with "Great Stuff". Maybe that's what they used (?)
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Old 10-21-2015, 07:43 PM   #10
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Interesting, all the champions I have seen have been fiberglass?

So this has metal ribs and roof like a school bus

Sorry to see this, so it wasn't obvious from up top?

Like Tango said some chemical must have reacted with the metal, very weird....wonder what kid of fumes it put into the bus as it was working? Even big leaks at every panel wouldn't do that....every surface was affected

So what does the roof look like? (Minus the hole in it)

Might be better off to sell engine, tranny rear end (whole thing) and find another one, my worry for you was rotten floor wood and worst case replacing some metal floor joists

Again sorry to see this
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