Rusty 87 build thread

[ol trunt]

Fun when you figure out that kind of stuff isn't it?
Jack

[banman]

Are you reinstalling the emergency window handles?

If not can you post a pic? One of mine broke off...

[musigenesis]

Originally Posted by banman

Are you reinstalling the emergency window handles?

If not can you post a pic? One of mine broke off...

They're yours if you want them (I'm not reinstalling them because these windows will be fixed in place). The two holes in them are exactly 3.5" center-to-center.

[musigenesis]

The rails take three bolts but I've left out the middle one on each rail in this diagram for simplicity. The bolt for the rail closest to the driver's seat has a stiffener almost directly underneath (but slightly offset) that is in the way, although this stiffener ends before it gets to the other rail (it's weird, this is the only stiffener on the floor of the bus that doesn't go all the way to the wall).

I think I am going to cut this stiffener back so that it's not below the inner rail either, and then run a third angle steel underbody bracket between the two rails. This one may be wider than the other two (maybe even running out to the wall) and I'll also bolt it to the floor. Like so:



I'm not going to be welding anything for this mounting, it will all be 1/2"-20 Grade 8 bolts and nuts.

[Native]

Originally Posted by musigenesis

Attachment 44627

The rails take three bolts but I've left out the middle one on each rail in this diagram for simplicity. The bolt for the rail closest to the driver's seat has a stiffener almost directly underneath (but slightly offset) that is in the way, although this stiffener ends before it gets to the other rail (it's weird, this is the only stiffener on the floor of the bus that doesn't go all the way to the wall).

I think I am going to cut this stiffener back so that it's not below the inner rail either, and then run a third angle steel underbody bracket between the two rails. This one may be wider than the other two (maybe even running out to the wall) and I'll also bolt it to the floor. Like so:

Attachment 44629





I'm not going to be welding anything for this mounting, it will all be 1/2"-20 Grade 8 bolts and nuts.

I think those short floor supports are called outriggers. Cutting a little off will not harm the structure considering you are adding stiffening with the mounting brackets.

[Frochevy]

Originally Posted by kidharris

I think that I would want it to stop whatever was making it shatter, so I would keep worrying.

Very good point!!

[banman]

Originally Posted by musigenesis

They're yours if you want them (I'm not reinstalling them because these windows will be fixed in place). The two holes in them are exactly 3.5" center-to-center.

Attachment 44626

Sweet -- they look and measure identical.

PM sent...

[musigenesis]

[banman]

Welds are looking better.
For those tabs on the floor (for example) if you can see the other side of the metal they're welded to -- you can get a good idea of penetration by the color/heat pattern showing on the back side of the metal they're welded to.

Your bulkheads coming along -- If you're still doing a layer of expanded metal mesh you can consider adding an entry level lock to the door for increased security of your living space...

[musigenesis]

Welded tabs on the frame to match the tabs on the bus. Once the wall is complete I'll clamp it in place and drill holes for the 1/4"-20 bolts to hold it permanently.







Fitted the piece for the top of the frame by hammering it on an anvil and checking fit against the rib.

[musigenesis]

Originally Posted by banman

Welds are looking better.
For those tabs on the floor (for example) if you can see the other side of the metal they're welded to -- you can get a good idea of penetration by the color/heat pattern showing on the back side of the metal they're welded to.

Your bulkheads coming along -- If you're still doing a layer of expanded metal mesh you can consider adding an entry level lock to the door for increased security of your living space...

I'm still doing the expanded metal (except for the window) and I'm going to have a separate lock on the bulkhead door. My thought is that if I ever have to leave the bus at the shop I can lock that door and keep my living space secure.

Other side of the metal my floor tabs are welded to is just rust and tar.

[Native]

I do like your progress ... and really dig the matching curve. What was your technique for forming the curve?

[musigenesis]

Originally Posted by Native

I do like your progress ... and really dig the matching curve. What was your technique for forming the curve?

Thanks. I just used a mallet and an anvil and banged away until it matched the curve. I marked out the length I needed on the nearby rib and used that to check the curve on my piece until it matched well enough. This 1/8"x1" flat bar is pretty easy to bend like this.

[Frochevy]

Great work! I agree you are getting better at metal working and welds looking better. In my opinion there is something magical about taking a flat piece of steel and manipulating it into something you want/need .. keep it up!!

[musigenesis]

Originally Posted by Frochevy

Great work! I agree you are getting better at metal working and welds looking better. In my opinion there is something magical about taking a flat piece of steel and manipulating it into something you want/need .. keep it up!!

Thanks. I think one of the big parts of my welding improvement is that I'm doing a much better job of prepping everything down to bare metal now. When I first started welding floor patches in the back, I'm not sure I even did any prep at all, just patches onto rust. In fact, I'm really trying to fight the urge to redo the whole floor back there with the 4'x8' sheet of 14 ga. I have in my shed.

[musigenesis]

Expanded is such a pain to cut with an angle grinder. If you're cutting across the wire it's like butter, but trying to cut through the joins the long way takes forever. I just score the joins bend the sheet back and forth until they separate.









As I was tacking on the expanded I was telling myself "don't tack the top in case the curved piece doesn't fit afterward". I tacked the top and now it doesn't fit. Easy to grind off the tack, but I should maybe listen to myself occasionally.

[Frochevy]

Originally Posted by musigenesis

Thanks. I think one of the big parts of my welding improvement is that I'm doing a much better job of prepping everything down to bare metal now. When I first started welding floor patches in the back, I'm not sure I even did any prep at all, just patches onto rust. In fact, I'm really trying to fight the urge to redo the whole floor back there with the 4'x8' sheet of 14 ga. I have in my shed.

I went through the same ordeal just shorter bus. I ended up removing all and put new sheets back in...

[JDSquared]

I'm thinking of all the people who bought prison buses and tore all that metal cage out.

[musigenesis]

I'm so excited. I haven't bought new flap disks or grinding wheels since last summer, so it's been an endless process of finding the least useless worn out ones in my bin. It finally occurred to me to just order big stacks of both and they just showed up.

[musigenesis]

Originally Posted by JDSquared

I'm thinking of all the people who bought prison buses and tore all that metal cage out.

That's exactly what I've been thinking as I've been building this.