Shenandoah the Toy Hauler

[trx]

It sounds similar to the to my conversation project. I didn't raise the roof, I cut it off and built a new one. It's been sitting for a couple years but I'm going to use it again over memorial weekend.

[Sleddgracer]

Originally Posted by trx

It sounds similar to the to my conversation project. I didn't raise the roof, I cut it off and built a new one. It's been sitting for a couple years but I'm going to use it again over memorial weekend.

I kind of like the looks of that - looks mean!

[Ghaniba]

Originally Posted by trx

It sounds similar to the to my conversation project. I didn't raise the roof, I cut it off and built a new one. It's been sitting for a couple years but I'm going to use it again over memorial weekend.

I think what i like most of that is you've basically made it NOT a bus. Great work. I don't love the idea of a flat roof out in the weather, but I think if I was to do mine again, I might have to consider it. Maybe my next one! Which leads me now... To updates!

[Ghaniba]

I wasn't sure if it would.. but it fits in my barn!!! I knew height would be fine, but length was my concern. It fits! Unfortunately, I'll have to pour some concrete though to be done. Originally, we kicked out the length for the overhang past the axles of a very large trailer, but the old axles never left the concrete... Now, this engine and front axles are on wood. Thankfully, its overbuilt enough to do it, but I look forward to it being a slab instead.





Once it fit, we built the fine adjusters for four corners during the roof raise. Some allthread, couple big nuts & washers, and welded them into place.





Grinding, grinding, grinding... My god, that was a lot of grinding. The whole top of the first rub rail, and the whole bottom row above the windows. I highly recommend the harbor freight scaffolding. That was worth the money. And many people grinding -- having friends here -- I can't thank them all enough!!

[Ghaniba]

We did the two floor jacks and some 4x4 for the actual lifting. Height I decided to stop at 12" - I was originally thinking of doing 20" but I wanted to have more room for solar AC etc without losing my ability to fit in this bay. It came out awesome.

[Ghaniba]

1-1/4" sq tubing worked PERFECT. Tapped it in with a nice heavy hammer to start it straight then used some c-clamps from harbor freight to suck it in. Some of the hat channel got squeezed in at the sides too, for a tighter fit on welding.

[Ghaniba]

PRO TIP:

No pictures of this, but grinding off the galvanizing coating on the hat channel is a huge PITA. I found a 7" grinder with a flap disk worked best to reach inside and clean where welding.

[Ghaniba]

During the raise, we cut out a bit of the back in preparation for the rear loading door/ramp. Many sketched ideas were done on our small yellow notepad!

Love it. The ramp had gone through about a dozen revisions. I won't reveal that yet, but it's going to be nice, AND have some wow factor too.

[Ghaniba]

At this point, building a project this big makes you start having some stress. It's big. It's got tons of moving parts.

Go get some dinner, and free advice like I did.

Relax, just go do one thing. The long road is traversed a single step at a time!

[Ghaniba]

More welding, more cutting piles build up.. but now she's OPEN!

[HazMatt]

Very sneaky! Here I was thinking a legal pad, until I scrolled the photos!
How is the roof's level? It may only be due to the camera angle, but the driver's side looks a scootch lower than the shotgun side in pic 2.

[Ghaniba]

Originally Posted by haz.matt.1960

Very sneaky! Here I was thinking a legal pad, until I scrolled the photos!
How is the roof's level? It may only be due to the camera angle, but the driver's side looks a scootch lower than the shotgun side in pic 2.

It's all measured exactly even on every extension, I think cameras and eyes just play tricks on us.

Dave aka Ghan

[Ghaniba]

Tragedy strikes.

Anyone who's used grinders know, they will try to bite you. It doesn't matter how much you've used them, the longer you use them, the more chance you'll have to be bit. You plan how you're holding it, plan for kickback, wear the right gear on eyes, ears and hands, but it is ALWAYS a risk. You end up in odd positions using grinders all the time.

One of the guys too a hit, and a pretty good one. He continued to grind away a couple more, but realized when he lowered his hand and the flow of something hit his fingertips... It was worse than it felt!

Sorry for the graphic imagery, but I think it's worth the post. Accidents happen.

We immediately broke out the first aid kit on the bus! No stitches required, but it was good n' deep.

This led me to a lot of reflection that night. What if he severed a hand. The guy in question works with me on a daily basis. We do computer related jobs for a living. He might never type again.

Was I crazy to be letting people help? I'm not worried about law suits, but just how would i not be indebted to someone who was severely injured working on MY silly project!?

I came to terms with this. Basically, every single person helping me has sent me a text, thanking me for having them involved in the project. It's been an amazing experience. Everyone has opinions, and I welcome all of them. Different views makes great plans. Seeing weekness one didn't see in one idea, or another slight variation that makes it stronger or better in some way. Invaluable!!!

With that said - this project is bigger than me. It's almost like a band of Brothers scenario. Doing it together is amazing, and being involved is just a blessing to us all!

[HazMatt]

I didn't expect you relied on eyeballing it as good 'nuff!
Couldn't not say something too late, tho 2 posts popped up while writing showing the weld work proceeding!
Thankfully, just parallax error after all... [emoji106]

Originally Posted by Ghaniba

It's all measured exactly even on every extension, I think cameras and eyes just play tricks on us.

Dave aka Ghan

[HazMatt]

Thank Dawg the injury wasn't worse that it was!!!

[tugboater]

Originally Posted by Ghaniba

Tragedy strikes.

Thanks for sharing. Glad to see nothing too terrible happened. I have a little scar right across my sternum from a grinder....lucky no stitches. Still have the shirt it cut a 4" hole through. I was a welders helper for a while back in the 90's, he kept a helmet hung on his van wall to show all us kids. It had half a cutting disc that had exploded, lodged in it. Imagine what that would have done to a simple face shield.

Last year we hired a welder for a project on one of our boats. I ran around Anchorage buying up supplies with him. He showed me a Dewalt grinder that he uses now. Told me he won't use any other type. It doesn't kick....I tried it. A little expensive, but probably worth it if you use it all the time...or if you're not experienced with one. I'm sure all the major tool manufacturers make a version of it by now.

[Ghaniba]

Curious, what is the rigging to make it not kick? Interested!

[Ghaniba]

Boy I'm overdue for an update!

So, we're building a ramp door, so we needed a nice, true surface to land against. We spaced it out 1/4" for a seal in the future as we began to make the ramp door itself.

4 Hinges were bought from Amazon, couldn't make them myself for the price, under $50 for all 4, each rated for 900lbs... And we'll probably need most of that.



We used a very nice, large piece of angle iron to bridge from the floor down to the rear bumper. Tied into the rear bumper with some 1/2" steel rod for the gaps. This basically made the whole rear end of the bus one very large piece. Worked great, and gave us a perfect flat area to begin the actual ramp!

[Ghaniba]

Ramp door frame began to come together, being built from some rough sketches.


We built it in the upright position to make our lives easier. Lots of clamps, and tack welds and we officially had a moving framework.

You may notice, the ends are open... and the sketch shows two parts - I wanted the ability to make an easier angle for motorcycles...

[Ghaniba]

The primary ramp, and the secondary ramp, fully extended. I have no intention to make it THAT long, but it's nice to have some overlap. My plan is 80" primary, 40" secondary kick out.


Slides in and closes up nicely!