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Old 07-28-2019, 09:56 AM   #1
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Shuttle bus window removal. I need help with how to patch holes.

Hello everyone,

I have a shuttle bus that I plan on removing 2 windows. This is a fiberglass body and need help with what to do with those holes once I do. I know on skoolies riveting in panels is the most common, but given my fiberglass body, using fiberglass to fill 36"x 30" holes seems like a huge task for someone who had never worked with fiberglass.

Thanks for any help.

The windows being removed are Able windows which I cannot find replacement parts for.

Also both windows will be near my bed, one of which is an emergency exit, but I have the wheel chair access at the feet of my bed.
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Old 07-28-2019, 11:16 AM   #2
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Hello everyone,

I have a shuttle bus that I plan on removing 2 windows. This is a fiberglass body and need help with what to do with those holes once I do. I know on skoolies riveting in panels is the most common, but given my fiberglass body, using fiberglass to fill 36"x 30" holes seems like a huge task for someone who had never worked with fiberglass.

Thanks for any help.

The windows being removed are Able windows which I cannot find replacement parts for.

Also both windows will be near my bed, one of which is an emergency exit, but I have the wheel chair access at the feet of my bed.
fiber glass is quite easy really - pick up a book or even watch some videos - the technology goes back 1000's of years with the Chinese using silk and lacquer to make incredibly strong objects - the only difference between what they did and are still doing is that we use one or more types of fiber glass and resins to make our incredibly strong objects - it's simple matter of soaking the fibre glass in resin and forming it in place or in a mold, sand and paint ( and maybe using a bit of bondo here and there - if you have a chance of going to see how boats are made, it will take you ten minutes of watching and you will know exactly what to do - it's not rocket science
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Old 07-28-2019, 04:13 PM   #3
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The issue is that because they're vertical I don't know how to get it the fiberglass to stay without gravity winning.
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Old 07-28-2019, 04:19 PM   #4
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I would cover the opening from the inside with thin plywood (door skins) then coat the outside with resin. Then press the cloth into the resin and then finish wetting out the cloth with resin.
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Old 07-28-2019, 04:22 PM   #5
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The issue is that because they're vertical I don't know how to get it the fiberglass to stay without gravity winning.
lay it out on the flat - build it to the thickness you want, then trim to fit your opening - cut some cardboard as a template - set it in place and use some resin filled bands of fibre glass over the crack where they join to hold it all in place - on the exterior, fill any cracks with bondo ( shouldn't take much ), sand and paint to match
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Old 07-28-2019, 04:26 PM   #6
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I would cover the opening from the inside with thin plywood (door skins) then coat the outside with resin. Then press the cloth into the resin and then finish wetting out the cloth with resin.
Thank you. I'll trace the opening an fill it with plywood. I'll make sure I leave enough of a depression to allow 2-3 layers of fiberglass. I'll finish it with gel coat.

So, where's the best place to buy fiberglass materials from?
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Old 07-28-2019, 04:35 PM   #7
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Thank you. I'll trace the opening an fill it with plywood. I'll make sure I leave enough of a depression to allow 2-3 layers of fiberglass. I'll finish it with gel coat.

So, where's the best place to buy fiberglass materials from?
Kind of depends on where you are.......... Your profile says you are nowhere......

I get mine from Fiberglass Mart on Hwy 99 in Lynnwood.
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Old 07-28-2019, 04:46 PM   #8
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I would cover the opening from the inside with thin plywood (door skins) then coat the outside with resin. Then press the cloth into the resin and then finish wetting out the cloth with resin.
here's a video of building a sheet of fibre glass - you can make it any size you want - be sure to start with a well waxed very smooth surface because that surface is what the world is going to see

https://www.google.com/search?q=maki...D8fF-gS6750421
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Old 07-29-2019, 01:08 AM   #9
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Lay multiple layers and LOTS of resin. Each part of the fiberglass must be soaked or you will have dry pockets that are very weak, brittle, and allow water to penetrate into the voids. Also, WEAR GLOVES ... and perhaps a respirator.
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Old 08-02-2019, 06:23 AM   #10
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Thanks for the great advice. I know fiberglass comes in different weights, so I will research which is most beneficial/forgiving. Is there a resin I should use?
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