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08-29-2019, 06:28 AM
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#81
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Bus Geek
Join Date: Sep 2014
Location: Eustis FLORIDA
Posts: 23,764
Year: 1999
Coachwork: Thomas
Chassis: Freighliner FS65
Engine: Cat 3126
Rated Cap: 15
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Looks like classified gov't top secret bus pics.
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08-29-2019, 04:47 PM
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#82
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Bus Geek
Join Date: Jan 2019
Location: Philadelphia
Posts: 7,000
Year: 2003
Coachwork: International
Chassis: CE 300
Engine: DT466e
Rated Cap: 65C-43A
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More bondo and my new mail slot
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08-29-2019, 11:14 PM
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#83
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Bus Geek
Join Date: Jan 2019
Location: Philadelphia
Posts: 7,000
Year: 2003
Coachwork: International
Chassis: CE 300
Engine: DT466e
Rated Cap: 65C-43A
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Quote:
Originally Posted by EastCoastCB
Looks like classified gov't top secret bus pics.
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It's a combination of not wanting to show my license plate number and not wanting to see my own bald head.
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08-31-2019, 07:02 PM
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#84
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Bus Geek
Join Date: Jan 2019
Location: Philadelphia
Posts: 7,000
Year: 2003
Coachwork: International
Chassis: CE 300
Engine: DT466e
Rated Cap: 65C-43A
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Starting on repairing other corner
I cut this piece and it fit perfectly first time. Never happened before.
And then I welded it in place in my usual haphazard style. That has happened before.
Welded hole patch experiment.
More frankenwelding to stitch on the new outside panel. I somehow keep convincing myself that I will be able to weld over 1/8" gaps when in fact I can't.
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09-04-2019, 07:28 AM
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#85
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Bus Nut
Join Date: Apr 2018
Location: Barrie ON
Posts: 440
Year: 1997
Coachwork: Thomas
Chassis: International
Engine: T444E
Rated Cap: 72
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looking good, keep cracking on
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09-11-2019, 07:29 PM
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#86
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Bus Geek
Join Date: Jan 2019
Location: Philadelphia
Posts: 7,000
Year: 2003
Coachwork: International
Chassis: CE 300
Engine: DT466e
Rated Cap: 65C-43A
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Mondo bondo
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09-12-2019, 08:51 PM
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#87
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Bus Geek
Join Date: Jan 2019
Location: Philadelphia
Posts: 7,000
Year: 2003
Coachwork: International
Chassis: CE 300
Engine: DT466e
Rated Cap: 65C-43A
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09-13-2019, 04:16 PM
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#88
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Bus Geek
Join Date: Jan 2019
Location: Philadelphia
Posts: 7,000
Year: 2003
Coachwork: International
Chassis: CE 300
Engine: DT466e
Rated Cap: 65C-43A
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Welded floor patches
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09-20-2019, 05:23 PM
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#89
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Bus Geek
Join Date: Jan 2019
Location: Philadelphia
Posts: 7,000
Year: 2003
Coachwork: International
Chassis: CE 300
Engine: DT466e
Rated Cap: 65C-43A
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Rear light panel reinforcement: fun with rivnuts
1/8" galvanized plate cut to fit behind lights ($8.25 for a 48" x 8" piece, love me some Fazzio's):
Locked into position with four 1/4-20 screws. These may not have been necessary but they held it in place initially and will at least take some stress off the rivnuts.
Closed-end rivnuts in place of the original sheet metal screw holes. My initial attempt at placing one of these a few days ago resulted in the rivnut nosepiece breaking. This time I clamped the two pieces (original bus body and new plate) tightly with small c-clamps through the center hole, and then I had enough chooch to crimp the rivnuts properly without snapping the nosepiece. Rivnuts went in "wet" with seam sealer.
This might be overkill for the lights, but these openings were a major source of leakage (both from the big holes and the screw holes) and I want to make sure these stay dry.
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09-23-2019, 07:22 AM
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#90
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Bus Nut
Join Date: Apr 2018
Location: Barrie ON
Posts: 440
Year: 1997
Coachwork: Thomas
Chassis: International
Engine: T444E
Rated Cap: 72
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It's about what gives you piece of mind, or at least that's what I tell myself when I over engineer the crap out of something.
If nothing else, you're refining you rivet smashing processes...
My load standards officer use to say "don't practice until you can do it.... practice until you can't f@ck it up"
looks good
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09-24-2019, 06:20 PM
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#91
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Bus Geek
Join Date: Jan 2019
Location: Philadelphia
Posts: 7,000
Year: 2003
Coachwork: International
Chassis: CE 300
Engine: DT466e
Rated Cap: 65C-43A
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Right side light reinforcement
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09-24-2019, 08:09 PM
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#92
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Bus Crazy
Join Date: Aug 2019
Location: Moved to Zealand!
Posts: 1,517
Year: 2002
Coachwork: Thomas
Chassis: Freightliner FS-65
Engine: 7.2L Cat 3126 turbo diesel
Rated Cap: 71 passenger 30,000 gvwr
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Great effort!
Way to eat the elephant, one bite at a time!
I like a product called "duroglass". It's like bondo BUT it's structural having long glass fibers and a more epoxy like base.
For welding across a sheet-metal gap -- If you have access to both sides -- hold a piece of copper tube or plate under the gap. It will keep the weld puddle from falling through and the weld won't stick to the copper.
I'm on the road so no access to my saved links but getting a better helmet with a bigger screen will quickly make you a better welder. I don't mean a $200 Lincoln helmet either -- good stuff for under a $100 but HF ain't it.
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09-24-2019, 08:18 PM
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#93
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Bus Geek
Join Date: Jan 2019
Location: Philadelphia
Posts: 7,000
Year: 2003
Coachwork: International
Chassis: CE 300
Engine: DT466e
Rated Cap: 65C-43A
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Quote:
Originally Posted by banman
Great effort!
Way to eat the elephant, one bite at a time!
I like a product called "duroglass". It's like bondo BUT it's structural having long glass fibers and a more epoxy like base.
For welding across a sheet-metal gap -- If you have access to both sides -- hold a piece of copper tube or plate under the gap. It will keep the weld puddle from falling through and the weld won't stick to the copper.
I'm on the road so no access to my saved links but getting a better helmet with a bigger screen will quickly make you a better welder. I don't mean a $200 Lincoln helmet either -- good stuff for under a $100 but HF ain't it.
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If I can get a helper, I may try having them hold a copper plate under the small holes when I weld them over so I don't have to create a giant metal turd to do it. Thanks for the tip on that. That's something that would have been very useful when I was welding the bent piece of angle iron for my corner repair.
I hear you on the helmet.
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09-26-2019, 04:19 PM
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#94
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Bus Geek
Join Date: Jan 2019
Location: Philadelphia
Posts: 7,000
Year: 2003
Coachwork: International
Chassis: CE 300
Engine: DT466e
Rated Cap: 65C-43A
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09-28-2019, 07:41 PM
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#95
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Mini-Skoolie
Join Date: Oct 2016
Posts: 34
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Nice work.
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09-29-2019, 10:18 AM
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#96
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Bus Geek
Join Date: Jan 2019
Location: Philadelphia
Posts: 7,000
Year: 2003
Coachwork: International
Chassis: CE 300
Engine: DT466e
Rated Cap: 65C-43A
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Priming and new tailights
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09-29-2019, 02:02 PM
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#97
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Bus Crazy
Join Date: Aug 2019
Location: Moved to Zealand!
Posts: 1,517
Year: 2002
Coachwork: Thomas
Chassis: Freightliner FS-65
Engine: 7.2L Cat 3126 turbo diesel
Rated Cap: 71 passenger 30,000 gvwr
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The licence plate light should be wired to come on/off with the parking/running lights.
No need for a separate circuit, and for sure NOT always left on.
Just splice it to the tail light wire.
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09-29-2019, 03:56 PM
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#98
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Bus Geek
Join Date: Dec 2017
Location: Dawsonville, Ga.
Posts: 10,482
Year: 1999
Coachwork: Genesis
Chassis: International
Engine: DT466/3060
Rated Cap: 77
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The license plate light bulb is the running light bulb, there's just a clear lens under it. Where are they leaking from? The wire hole? Have you used a proper grommet for sealing hole and wire?
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10-02-2019, 02:36 AM
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#99
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Bus Geek
Join Date: Sep 2015
Posts: 3,856
Year: 2002
Coachwork: Thomas Built Bus
Chassis: Freightliner FS65
Engine: Caterpillar 3126E Diesel
Rated Cap: 71 Passenger- 30,000 lbs.
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Hey Musigenisis ... rust remediation is a tough job. Your bus and ours both suffer from the wheel well rot and the back light drip. I sympathize with you. However, it does feel GREAT to get rid of a hunk of RUST and make it solid again. Keep up the good work.
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10-02-2019, 05:59 AM
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#100
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Bus Geek
Join Date: Jan 2019
Location: Philadelphia
Posts: 7,000
Year: 2003
Coachwork: International
Chassis: CE 300
Engine: DT466e
Rated Cap: 65C-43A
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Quote:
Originally Posted by Native
Hey Musigenisis ... rust remediation is a tough job. Your bus and ours both suffer from the wheel well rot and the back light drip. I sympathize with you. However, it does feel GREAT to get rid of a hunk of RUST and make it solid again. Keep up the good work.
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Thanks, man, appreciate the kind words. It is indeed tough but I feel all this work is giving me more of an emotional attachment to this hunk of steel ... which is probably going to lead to more bad decisions down the road.
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