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Old 10-23-2022, 11:22 PM   #2461
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Trimmed and padded the XPS pieces for four more inserts.

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Cut a ton of square pegs at 8:30 in the morning. Probably not the most neighborly thing for a Sunday.

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Milled out the holes using a 1/2" bit for the center and then a 1/4" bit for the corners. There's enough give in XPS that this was adequate for inserting the pegs, with some construction adhesive put in first.

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I want to say the pegs pushed in easily but they actually required a bit of violence.

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All eight pieces done.

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Fitting the plywood facings.

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I forgot I was going to have this piece fit into the small gap under the overhead storage. I guess I'll just glue a little sliver here instead.

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Sigh, all day Sunday and I couldn't even finish these four inserts. That's what I get for wasting my time watching the Browns.

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Old 10-26-2022, 05:53 AM   #2462
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Four more inserts in the back completed.

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Just found out these white hinges are not available online any more, so I'm going to have to use a different type for the rest of these.

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Seven down and twenty to go.

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Corn hole saw with the perfect radius once again.

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Corners cut on the bandsaw.

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After much sanding, a perfect fit.

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These blocks are attached temporarily with pins, to keep the inserts from going in too far when I screw in the facing.

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Checking to see if any light gets around the edges of these things. My stealth dreams are still alive.

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This one required not much sanding to fit. The skoolie experience: getting good at something once you don't have any more of it to do.

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Old 10-27-2022, 08:58 PM   #2463
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Wow..

Great job on the build.
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Old 10-27-2022, 10:14 PM   #2464
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Put in the foam inserts for the back door window. This one will also be hinged in the hopes of being able to put it in and take it out without removing the top latch bar first, but I'm not sure that will work. No big deal if it doesn't, removing the latch bar just requires undoing one nut.

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Test-fitted my precut pieces for three more windows. Once again they don't fit very well.

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So gloomy in the back now with all these in place. My self-propelled temporary coffin is coming along nicely.

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I put the back pieces in over the last couple of days when it was a bit chilly and cloudy. This afternoon I took them out after a day of the back end of my bus baking in direct sunlight and it was nearly impossible to get them out since the wood framing around them had expanded so much in the heat.

I think I've been too concerned about getting these foam pieces to fit perfectly. I don't want them to be impossible to get in and out except when the bus is cold, and even with some considerable gaps in these back pieces (you can see the light coming through around them in these pics), the back wall was still cool even with the windows too hot to touch. For the remainder of my inserts I'm going to go for a looser fit.

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Glued in the square plugs for these back pieces.

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Old 10-27-2022, 10:18 PM   #2465
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Wow..

Great job on the build.
Thank you very much.
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Old 10-30-2022, 09:33 PM   #2466
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Carved up my last piece of underlayment plywood.

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Finished up my rear wall window inserts.

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Nice and gloomy back here now!

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Took this because I realized I don't have a good photo highlighting just my dropped kitchen floor. And I still don't.

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Old 10-30-2022, 10:21 PM   #2467
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Wow

Wow. That looks terrific inside. Pick & choose views. Private limo service, VIP room in the back. Insulated for sound, sight, & temp...
(Halloween soon, 🎃 scream tested, yet?)


I especially like how well they look at night. Stealth.

You'll likely inspire many of us to make a few insulated window panels, too.
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Old 10-31-2022, 07:58 AM   #2468
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I love the idea of removable inserts like those! i love lots of light but would be nice to be able to insulate if i need to so I could have a half a chance of staying cool parked with my portable A/C.. as it is now if its sunny out I wont even feel the 12k A/C.. at night its a freezer if I want it to be.. im sure all those non tinted tall windows i love the bus for are the culprits
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Old 10-31-2022, 12:25 PM   #2469
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(Halloween soon, 🎃 scream tested, yet?)
I can't wait to get these all done so I can test out the sound insulation. Weirdly enough, I'm not as concerned about blocking outside noise as I am about blocking inside noise - I want to be able to play my music loud without disturbing my neighbors.

Or, y'know, dismember my victims. Bwah hah hah hah! I choose "trick".
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Old 11-01-2022, 09:56 AM   #2470
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Looking awesome!
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Old 11-05-2022, 11:56 PM   #2471
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Finished fitting all the XPS pieces of the windows, so this is lit only by the skyhatch.

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Decided I might as well fit the XPS to seal up the skyhatch as well. The kerfs are to allow it to bend slightly, but I should have put them on the inside. It needs more kerfs, too, but I'm really afraid of breaking this piece.

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Needs just a little more sanding to fit all the way in, and then I have to carve cutouts in the back side to fit over the hinge and the handle.

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Old 11-07-2022, 09:46 PM   #2472
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Some cutaways for the skyhatch insert to fit around the hinge and the handle. Put some shims into the kerfs so it naturally bends to fit the slight curvature of the hatch.

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Finished padding and shaving the rest of the XPS blocks for the window inserts. Need to put the square pegs in all of these blocks now so I can finish the inserts. Hopefully I can speed this process up a bit.

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I'm probably not going to be able to paint the inside part of any of these inserts before next spring unless we get some freak warm weather, but I'm going to have to paint the outsides black now to protect the XPS from UV.

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More trim to paint. I took out the rear inserts because I kind of need to see out the back windows in order to park the bus in my storage lot.

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Old 11-08-2022, 08:45 PM   #2473
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Swapped out the hinges on my back inserts. I need to reserve the larger ones with removable pins for the inserts that have to go behind my kitchen counters. To get them in place I will probably have to remove the pins and insert the lower pieces first, since there isn't much clearance between the countertops and the window openings.

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Nice to have the back all open again. I removed all the inserts so I can paint the backs of them black.

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Test piece to determine the angle of the foam board for covering my Maxxair opening. Somehow, so many of the weird angles I need for stuff in this bus turn out to be 23°.

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Cut the piece for the fan opening, kerfed and wedged the backside, and then broke a chunk of it off. This turned out to be fortuitous as this was a lot easier to fit in two pieces anyway, and probably what I should have done from the beginning.

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Put my dumbbells back in the dumbbell drawer. Almost broke an ankle getting these 50 pound beasts down my garage attic folding stairs.

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Fit the remaining piece of foam around the fan projection.

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The remaining space was much less than 2" deep anyway, so it was a lot easier to sand down a piece of 1.5" XPS board to fit around the fan.

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Just needs the plywood face now.

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Old 11-18-2022, 06:54 PM   #2474
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Painted the out sides of all my foam board black. Black will look the best (stealthiest) from the outside, and it will maximize heat in the winter. The paint will also protect the foam from UV. This Krylon paint goes on really easily and it seems to adhere to the foam board pretty well. Time will tell. It did require two coats for each piece.

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Put the square pegs into the rest of the foam board for the side windows. This actually went a lot faster doing it like this with all the boards lined up. Took me about three hours total today.

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Pilot holes with a big screwdriver.

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Initial holes with a 1/2" drill bit.

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Squared out with a 1/4" drill bit.

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Pegs inserted with a glob of construction adhesive underneath.

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Exposed ends covered with construction adhesive. Not sure this is really doing any good, but what the hell.

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Flipped the boards over and did the same on the other sides.

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Still have to do this for the rest of the funky-shaped blocks.
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Old 11-18-2022, 09:33 PM   #2475
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Up to page three in this incredible conversion, I have something to keep me motivated through the coming cold days now!
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Old 11-19-2022, 07:03 AM   #2476
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Up to page three in this incredible conversion, I have something to keep me motivated through the coming cold days now!
Thanks! I'm up to page 124 now, though - you might be on this until next winter.
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Old 11-26-2022, 09:05 PM   #2477
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Glued in the plywood pegs for the odd remaining bits of XPS inserts.

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In one of my earlier experiments I tried using 1/2" dowels through the foam instead of 1.25" and it did not work at all. Reusing the same piece for my entry door, gluing in pieces of dowel to fill the hole. Somehow this seemed like less work than just cutting a fresh piece of foam board - not sure what I'm thinking some of the time.

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Some pre-cut pieces of plywood for the inserts.

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To align the holes for the plywood faces, I mark where the plugs actually went with a square,

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and then transfer those marks to the plywood once the XPS is placed in the window frame.

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I attach the bottom pieces first.

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Then the top pieces go into place, after a great deal of hand-fitting because nothing is quite square.

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Made the cover and trim for the side exit door window.

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As I learned the hard way, Revolutionply underlayment is not naturally bendy enough to take the sharpest portion of the ceiling curvature. This is right where the vent fan opening in the shower is, so I kerfed the back of the facing for the vent fan cover with a utility knife. Tremendous pain in the butt but it worked.

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Sort of worked, anyway. I had to put in extra clips to get the cover to bend fully against the ceiling. At least I don't need the clips anywhere else on the cover.

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Old 11-27-2022, 12:40 PM   #2478
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Thanks! I'm up to page 124 now, though - you might be on this until next winter.
Lol, I like a nice, long read in the winter!
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Old 11-27-2022, 10:32 PM   #2479
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Cut out the plywood facing for my skyhatch insert, scored the backside to make it more flexible, and screwed it to the foam piece.

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The foam is pretty snug so this stays up by itself.

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I didn't want to trim all around this because the corners are rounded and the screws holding up the original plastic hatch trim would be in the way, so I opted for little pieces of trim just large enough to hold each storm window clip.

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Just these four were enough to mostly hold it in place, but they didn't quite have the front and back edges completely flush and I wanted to have some additional clips holding the cover in place.

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It looks a bit weird to have all of the clips on just the front and back edges of the cover, but because of the curvature the other two edges are completely snug against the hatch trim and don't require any clips.

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Rusty 87 build thread
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Old 11-28-2022, 10:01 PM   #2480
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Join Date: Jan 2019
Location: Philadelphia
Posts: 6,654
Year: 2003
Coachwork: International
Chassis: CE 300
Engine: DT466e
Rated Cap: 65C-43A
Three of my inserts are behind my long countertop; I could place storm window clips down at the bottom but I could only access them from inside the cabinets (which aren't closed in the back) but that would be a royal pain. Instead I'm screwing in this beveled clip so I can just pop the inserts down from above.

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This little clip holds in the corner of the insert behind the fridge. I don't know why I didn't just use a storm window clip here.

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Countertop inserts with the backsplash for the counter put back in place. I was going to post some pics here of how easy it is to get the inserts in and out without removing the backsplash first, but it turns out I can't pull out the top pieces after removing the hinge pins. I have no idea what's causing them to stick but I suppose I'll figure it out eventually.

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Finished installing the clips and hinges for most of my remaining inserts.

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I had to remember to keep the bottom clips here out of the way of the folding desk when it's up.

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22 down and only these 3 inserts left to do. They're going to be tricky since the stove, sink and water half-wall are all in the way of the bottoms.

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