Ed's Build Thread

dbsoundman · 06-13-2021, 08:12 AM

Hi everyone, meet Ed.

Ed is a 2006 Thomas FE "transit"/cabover bus. Haven't counted the total seats but it's definitely "full sized". Cat C7 engine and Allison MD3060 transmission. Air brakes, nothing else all that special. It's an Ohio bus, so it's definitely got some rust, but it has been well cared for, so I think we'll be OK. I weighed the options of traveling states away to buy a bus sight unseen, but just couldn't stomach that idea, so I found Ed via Facebook in Columbus and took a truck driver/enthusiast friend with me to check it out.

We've already started removing the decals, although we're not enthusiastic about all the lettering hidden under a liberal slathering of black spray paint. I plan to start seat removal today. Have to do a small amount of rust treatment here and there on the exterior, give the underbelly a good power wash and oil treatment, and figure out the usual school bus wiring mysteries.

I also might have a fuel injector issue which only became apparent on the highway, usually when the engine was under "moderate" throttle, like when I hit the governor at 65 and start going up a slight incline - all of a sudden it sounds like there's a jackhammer going off in the engine compartment, but no noticeable loss of power or smoke.

Here's a photo dump, it's parked in my driveway so I can't get good pics of everything just yet. Let me know if you see anything that looks familiar to you, especially when it comes to the wiring compartment - I don't think the diagrams on the door match the panels that are in there anymore, and nothing is labeled.

https://imgur.com/a/EOgBgXo

dbsoundman · 06-29-2021, 08:44 PM

Look ma no seats!

Heading to the CAT dealership tomorrow for a full fluid change, filter change, and diagnostic. Tried to find an independent mechanic to work on it but didn't have any luck with the couple I tried and I'd like to get this done and out of the way. Hope they don't separate me from too much of my life's savings.

dbsoundman · 06-30-2021, 04:15 PM

Dropped off Ed at the CAT/Peterbuilt dealer today for service. Pray for my wallet. Just the basics: fluids, filters, and investigating an intermittent top end knock.

Bus'n it · 06-30-2021, 04:32 PM

Well, you can always take out a mortgage for the oil change! Shouldn’t be too bad. You are doing the right thing to have them look over it before you invest too much into the build for a problem down the road. I know I need to invest in new wheels/tires and to see why it leans to the left a bit. I’m sure I’ll need a 10 year note on the suspension repairs…

dbsoundman · 07-16-2021, 11:06 AM

Paid the CAT dealer about $1830 and change today. I'll post a pic of the invoice later for those that are interested. I still feel like the peace of mind is worth it, though I may shop around for quotes on the next oil change or consider getting all the tools here (provided the local stores will still recycle oil for free).

Pulling up the floor this weekend. I bought an air chisel to try, any other tips? Tricks?

dbsoundman · 07-16-2021, 12:45 PM

For those interested in the details, here's the invoice from the dealership. Top portion is for the overhead adjustment, the second portion is for an oil+filter change.

Also got a helpful printout showing the various specs and settings for my engine. Looks like I might have an option for cruise control if I can find the actual controls and wiring for it! And 231hp, not too shabby.

Also I put in some diesel today at Costco. $3.03 a gallon. Tank was at 3/8, filled it up to 7/8 full with 30 gallons, so evidently its a 60 gallon tank.

Jolly Roger bus 223 · 07-16-2021, 04:19 PM

it is nice having the full diag. sheet.
now you know what you have.
it looks like the shop supplies and labor is what jacked the price up?
i would look for cheaper air filters as well?
some times cheaper isnt always better though so be careful.

dbsoundman · 07-16-2021, 04:27 PM

Quote:

Originally Posted by Jolly Roger bus 223

it is nice having the full diag. sheet.
now you know what you have.
it looks like the shop supplies and labor is what jacked the price up?
i would look for cheaper air filters as well?
some times cheaper isnt always better though so be careful.

Shop fees were definitely high but I wasn’t really finding any shops that were enthusiastic about working on a CAT engine. Next service I’ll do more research.

The air filter is kind of a weird one, it’s this sort of cone shaped thing so I think i do have to special order it from the original dealer.

MNbusboy · 07-16-2021, 05:03 PM

I wonder if I can just get that printout from a dealership for my 04 with Cat 3126, and if they would charge me for it?

dbsoundman · 07-16-2021, 08:26 PM

Just realized that all of that work didn’t include replacing the fuel filter, fuel/water separator, or servicing the transmission. Slightly peeved about that. Should I be worried about servicing the transmission right now or just keep an eye on the fluid level and quality? I don’t know the age of the current filters but I also don’t know how often they should be changed.

dbsoundman · 07-18-2021, 09:13 PM

FLOOR REMOVAL! Wife did a TON of work pulling up the metal trim with a prybar, I only had to cut a few pieces with a grinder, then she cut all the plywood and pulled it up with a 36" crow bar.

All those little rusty spots have screws...all of the screws are still there. I have a LOT of grinding/cutoff work to do now. Still have to work around the bits under the heaters and hoses. Then it's time for metal repair, rust treatment, and some rusty metal primer.

Oscar1 · 07-18-2021, 09:29 PM

That's some awesome progress going on there

Cheers

musigenesis · 07-18-2021, 09:55 PM

I kinda envy you - it is soooo much fun to slather Ospho on that kind of rusty metal.

dbsoundman · 07-20-2021, 09:36 AM

Went to the DMV and title office today, I now have a registered motorhome in the state of Ohio!

dbsoundman · 07-22-2021, 08:07 PM

Went to look at the radio to figure out why it didn’t work the other night…attempted to hang the assembly by the wires to get a better look. Connector let go and the whole radio dropped. Two butt spliced wires broke off and I discovered another pair of mystery wires. Fun!

And I still don’t know where or if I have an external speaker…bus came with a mic and an “internal/external” switch but I can’t find an outside speaker anywhere!

dbsoundman · 07-28-2021, 09:00 PM

Took a closer look at the radio system today. Figured out the speaker wiring: the front two speakers are wires individually, but the back two on each side are wired in series. That way you can use a normal 4 channel car stereo amp. Also traces out all but one of the wires in the stereo wiring harness so I can pick up a cheap used stereo to try out. I’m thinking mine is just dead.

musigenesis · 07-28-2021, 09:10 PM

I ripped my speakers out during demo and then later deleted the stereo when I pulled the dashboard trim out for repainting. None of the gear was particularly good quality so it's not like I'm missing anything. You can have my stereo if you want it - it's even got a cassette deck!

dbsoundman · 07-29-2021, 06:22 AM

Quote:

Originally Posted by musigenesis

I ripped my speakers out during demo and then later deleted the stereo when I pulled the dashboard trim out for repainting. None of the gear was particularly good quality so it's not like I'm missing anything. You can have my stereo if you want it - it's even got a cassette deck!

What an insult - MY stereo has a CD player, you’re offering me a clear downgrade! LOL

I already found a few decks on marketplace for ~$20 that should do the trick. I’m sure the stock speakers stink but that’s a project for another day.

musigenesis · 07-29-2021, 06:29 AM

Quote:

Originally Posted by dbsoundman

What an insult - MY stereo has a CD player, you’re offering me a clear downgrade! LOL

I already found a few decks on marketplace for ~$20 that should do the trick. I’m sure the stock speakers stink but that’s a project for another day.

The cassette deck lets you plug in an adapter and hook up your phone! I was so excited when I saw this in my bus until I realized how stupid a thing that is to be excited about in a school bus.

dbsoundman · 08-02-2021, 08:33 PM

Floors are all out, aside from one tiny bit by some heater connections, and underneath the heater behind the driver's seat. That heater bolts through the floor and I'm not desperate enough to remove 2 square feet of plywood in a spot that's super out of the way anyway.

I have some patches to be made behind both rear wheels and the passenger side front wheel. I'm a little confused as to how the wheel wells fit together; it looks like there's the wheel well, then a really thin piece of metal (which has largely rusted away) filling the ~3" gap between the wheel well and the next floor piece. I'm not really sure if that piece is part of the wheel well, or if it's just welded in or what. Those are the main bits I need to replace and I'm not quite sure what I'll find once I cut away the bad stuff.

Can I just put a patch over the hole and seal it well, or should I do something special since it is in such a rust-prone spot? Experienced advice would be appreciated!

Oh, and the stairs have some holes in the front edge where salt hit them. Can I just patch that up with some L channel on the outside maybe?

Photo dump below.

Also, is there a quick and easy way to disable the alarms on the ceiling hatches? I wasn't sure if I could just cut the wires leading to the switch that's held down by the red handle, or if I needed to do something more elaborate.

Here's the little metal switch with the handle opened:

Wiring to the switch (feels like there's two wires, which makes sense):

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