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Old 05-03-2021, 10:58 PM   #1
Mini-Skoolie
 
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02 IC3800 T444E “sir wheelie”

Hello,
My wife and I recently started a conversion. I have been googling and searching ever since and am pumped I came across this forum. I’ll post some pics of the bus. I’ll show off our progress and we are welcome to ANY tips or feedback.

First, what does everyone think of the floor? Found out after pulling the seats and plywood that there was a massive amount of rust and leaky windows. Bottom of the bus looks great and engine runs awesome.
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Old 05-04-2021, 05:50 AM   #2
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That floor rust is relatively minor - a few coats of Ospho or other rust converter, prime and paint and you'll be good forever.

What is up with the last pic? Did you remove that large chunk of floor or was the bus already like this underneath the plywood?
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Old 05-04-2021, 07:06 AM   #3
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I pulled that part out. There was some rust going all the way through the floor right there. Gonna patch in some new sheet metal before I treat the rest of the bus and paint
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Old 05-04-2021, 08:28 AM   #4
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Quote:
Originally Posted by musigenesis View Post
What is up with the last pic? Did you remove that large chunk of floor or was the bus already like this underneath the plywood?
I pulled that part out. Probably overkill but I’ve got a good sheet of metal that was about that size. There were three spots within that area that was so eaten through when I went to pull the screws it ripped a hole. I figured if I’m building on top of it I’ll sure it up really well since I already have the metal. I’m gonna weld it in and coat the bottom.
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Old 05-04-2021, 09:22 AM   #5
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Nice shortie! even air-conditioned
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Old 05-05-2021, 12:10 PM   #6
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I think my floors are worse. You can see them in my thread "Leavuntaun - Soon".

If your bus is not rusty underneath then the rust was probably caused by the floor covering (rubber membrane over plywood) holding moisture against the sheet metal floor.

I'm only going to patch where necessary. I'll screw the patches down. On the floor your first step should be to clean and descale the floor. As Musigenesis will tell you it looks worse than it is. Once you've spent time cleaning the rust off it you'll be familiar with what you've got. I'd suggest you NOT cut large areas of floor out, at least not initially.
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Old 05-05-2021, 12:19 PM   #7
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I have personally witnessed bus employees use a water hose to wash out buses to clean them. Then we wonder why so much rust.
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Old 05-05-2021, 12:24 PM   #8
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if you are screwing or riveting patches down be sure to use something like 550 seam sealer between the metals, this will keep water from spraying up from underneath and rusting between layers of metal around your new patches
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Old 05-05-2021, 01:06 PM   #9
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Great feedback. I cut the large hole because I have a sheet metal piece that’s about that size. I plan to weld it in and then use some flex seal to coat the bottom then treat the top with the rest of the floor.
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Old 05-05-2021, 01:39 PM   #10
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Great feedback. I cut the large hole because I have a sheet metal piece that’s about that size. I plan to weld it in and then use some flex seal to coat the bottom then treat the top with the rest of the floor.
For the same area on my bus, I squared off umpteen billion smaller holes and welded on patches raggedy-ann-style. As I was doing it, I realized that an approach like you're planning is much better.
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Old 05-05-2021, 01:59 PM   #11
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I had started to do that but then realized the same thing. The sheet metal I have is a little thicker than the bus floor so I figured it would be better structurally to just get that piece in there
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Old 05-05-2021, 04:00 PM   #12
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Update on the build

Got some more work done over the past few days-

Floors out
Floors worked with a grinder and cup brush (pain)
Side panels out
Windows out
Most of the roof out
Insulation out
Excess wiring taken out
Camera system removed
Oil change
Fuel filter change
Took out the driver seat cause it was having some issues.... fixed and cleaned
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