So I got a little bit of work down on the inside rear engine cover.
Back in post #28 & 29 I showed where water was still trapped inside between the rear engine cover panels. Looking at the design as a whole, I feel very strong that the water intrusion begins at the air dam's and creeps it way in the bus in between the walls.
So the framing for the rear seats still had water in them after the bus being inside the warehouse for a year now...
I cleaned up all the rust it left behind, fortunately it wall all surface rust!
I left the foam inserts in place. Looking at them closely I'm guessing their not for insulation value but because of their design I'm guessing it is more for sound deadening.
Those foam panels have a vinyl sheet in the middle of the foam pads. So the foam must be for "diffusing" or "Absorption" of sound while the vinyl insert helps block sound.
I'll be gluing foam insulation boards over the whole thing anyway so leaving the inserts can't do anything negative for the bus.
I also took care of a huge hole in the floor, right under the heater! Wonder how long that must have leaked!
Where the inside mechanis acces panel is, I modified it slightly. I'm ditching my original thoughts of re-working the whole box to make it more "Sqaure". Instead I'll frame it out with wood when it comes time to do the insulation work.
I also cut out the "arch" that was right over the valve cover. I did this so I can at least "Square up" that center piece with a separate but removable insulated steel cover.
My diesel mechanic theorized that the arch was there in support of the lifting plates on the engine house frame. So out it goes as we will never need to use those lifting points!
Also on my mechanics recommendation, we cut out 3 inches from the interior rear wall, right on top of the valve cover. The thought here is that it will provide for more clearance so if you had to, you can get your arm up and over the valve cover from inside the engine box hopefully reducing or eliminating the need to remove the bed when and if the time comes to remove the head.
So in short, rust remediated, slight metal body mods and reassembly.
This afternoon I break the bus piggy bank and go buy some insulation boards. going 2 inch on the floor and 1 inch on the walls and ceiling.
It's been a while since I last posted on the progress of the bus, not that I stopped working on it, just pulled myself away from the computer for a while.
So I re-installed the foam mats that were found to be soaking wet all while the bus was inside the warehouse for at least 6 months....
Removed the arch in the center, cleaned all the metal, Ospho'd and rusty metal primered.
I re-installed the original sheet metal, glued down a 3/4 foam insulation board to the entire engine box and now covering with 5/8 plywood.
I also made the center "covers" fully insulated with sheet metal on both side, inside engine compartment and bus body. I designed this so that if access were needed for engine repairs, I could easily unscrew the cover plated and gain access without performing a major disassembly .
I also went ahead and finally changed the door from a bi-fold to a single door and mounted it on a piano hinge. I also re-utilized the fabric hinge cover so as to help protect the piano hinge from the elements.
I recycled some used steel from a UTV shipping crate.
The pic of the Yamaha sitting in the frame is an internet pic and the other rusted looking frame is a spare frame that I got. I originally got 2 of these...for FREE !!!
It is mild steel, approx 1/16" thick, perfect for a door frame!
The pieces I used to make a door frame in the bus is approx 1" x 2" and the center piece I welded in between the bifold doors is appox 1" x 4".
I made a rookie mistake when welding, I overheated one side while welding so now is has a slight "Bow", not perfectly straight. I tried to prevent this from the beginning by clamping down angle iron , top and bottom but what I did wrong is welded up one side first then flipped it around to do the other. That is when I overheated the one side and it bowed.
I should have done small tack weld first, on each side and then alternate my welding so as not to overheat any one side.
Added a piano hinge, door does close real nice but dang, I will still know the door is bowed!
So while on this adventure of rebuilding this bus, I went ahead and sourced some aluminum truck wheels. Found out real quick that the lugs were too short so off the wheels came so as to remove the lugs and buy longer ones. That's when it happened, hit me in the face hard... I NEED BRAKES AND DRUMS !!!
The pads were just about to start touching the rivets. If it wasn't for needing lugs I may not have looked into the brakes just yet. I also found a rear axle seal that was just starting to get moist.
One of the first things I did was to call the international dealer, give them my vin number and asked if they could email the build sheet for the bus. They did so quickly and again...FREE !!!
So my bus came with what the call 'California" brake pads. I have come to learn that they are actually "Merotir-Rockwell Q-plus" shoes.
The rear are 16.5 x 8 Q+ and the fronts are 16.5 x 6 Q+.
Every truck parts shop I went to did not stock them. They all tried to convince me to downgrade to the regular size shoes, rear 16.5 x 7 and front 16.6 x 5.
I said to them all, yeah right, while the whole world eagerly wants an upgrade you want me to downgrade my braking capacity???
I kept looking and found shoes... One place was really expensive but in all I spent so far $169.06 for the front shoes and $256.00 for the rear shoes. This place where I got the the front shoes did not care about the cores and would not subtract a core charge for the shoes. Oh well, I least I am gonna be safe now.
Still trying to source brake drums, I need to replace all 4. They have alot, i mean ALOT of heat cracks.
My local International dealer quoted me $207 each for the rear drums and $284 each for the front.
New axle seal, (2) for $120.00
That's $1,527 in parts alone. Glad I got it done now versus on the road broke down!
I wonder how much a break job costs for a bus?