The Broccoli Bus

[crazycal]

I'm glad there are people like you that make my feel completely inadequate. If I ever get a hair to do a roof raise, I will just come here and look at yours and some of the others that have been done to put that idea to rest. Nice work and carry on.

[skrapgiarc]

Originally Posted by crazycal

I'm glad there are people like you that make my feel completely inadequate. If I ever get a hair to do a roof raise, I will just come here and look at yours and some of the others that have been done to put that idea to rest. Nice work and carry on.

Exactly my thoughts!

[aaronsb]

Thanks for the compliments, it means a lot. I would add that my wife has been invaluable in helping me. She brings out ice water, coffee, snacks, and drags the jagged metal away from the vehicle before I trip and impale myself on it.

She doesn't read the forum regularly so I havent even been prompted.

Originally Posted by crazycal

I'm glad there are people like you that make my feel completely inadequate. If I ever get a hair to do a roof raise, I will just come here and look at yours and some of the others that have been done to put that idea to rest. Nice work and carry on.

[aaronsb]

I picked up 9 sheets of 4'x10'x20 gauge cold roll sheet metal today. I still need to get the right kind of rivets. Since I'm not using galvanized metal for the sides, I sort of figure it'll be ok to also use non-galvanized rivets as well as long as I paint everything quickly.

[browncrown]

Raise is looking sweet

[bansil]

Originally Posted by browncrown

Raise is looking sweet

X100

one of the best I have seen, great job!!

[aaronsb]

Got some metal. 9 sheets - heavy and awkward to move.


The very first two solid rivets I've installed in my life. Not too hard to do, but I can see there is a technique to it I will need to master.

[Tango]

Ahhh...no substitute for real, bucked rivets. Lookin' good!

[thjakits]

...looks like you need to get a slightly bigger driver head or clean up the one you have!

I don't know about steel rivets, but on Alu rivets it helped to soften the edges with masking tape.

Better solution is to slightly sand the outer edge and then polish the head.


Looking great so far!! Probably my favorite roof raise!!


Cheers,

thjakits

[aaronsb]

First sheet hung, a full 10 foot panel too!

Its just barely on with two rivets, tomorrow I have some helpers to hang the other 7 panels.

[aaronsb]

The driver is the right size I just was not in practice. They seem to look good now that I've tried a few more test rivets.

Originally Posted by thjakits

...looks like you need to get a slightly bigger driver head or clean up the one you have!

I don't know about steel rivets, but on Alu rivets it helped to soften the edges with masking tape.

Better solution is to slightly sand the outer edge and then polish the head.


Looking great so far!! Probably my favorite roof raise!!


Cheers,

thjakits

[aaronsb]

Most of the side panels hung. In the rain. Stupid Flanders - I mean, rain.

[aaronsb]

One more with the last big panel.

[aaronsb]

Getting some work done in the weather break.

I knew that re-building the door frames for the emergency exits would be a bit time consuming, but I think it's worth it to have the extra doors. I seam welded the edges back so they're constructed sort of like the original piece that was bent around the corner and riveted.

I'll be installing the original gutters above the doors, and I'm working on fabricating a new gutter that I can attach to the window "eyebrows" to form one continuous gutter across the high section.

I got my work lights set up for the days about to get shorter, and while I haven't driven in the side panel rivets yet, they will be done in the next few days. The rear rivets are mostly done - I used larger structural ones 1/4 inch to support the new cap structure I've built inside.


Photos below:

[thjakits]

WOW - you are fast!!

So - now that you showed us all how to do a proper and quick roof raise - why don't you just go ahead and build a few slide-outs too!!

Sittin' back and watching!


thjakits

[aaronsb]

I contemplated slideouts but ultimately decided against them because it goes against my thought that everything should be accessible and usable. An rv or bus with the slideouts closed is pretty cramped. I'm eventually aiming for a rather spartan interior that is serviceable and has technology in it to make things easier.

Slide outs fall too far into the category of marble countertops, slide out external televisions, and ornate and unnecessary fixtures in general.

Also, weight! Doubling up the panels and building a secure slideout systrm is heavy.

Originally Posted by thjakits

WOW - you are fast!!

So - now that you showed us all how to do a proper and quick roof raise - why don't you just go ahead and build a few slide-outs too!!

Sittin' back and watching!


thjakits

[Tango]

Great looking workmanship! Keep the pix a'comin'.

[bansil]

ugh...so when and where is the keger party?
.
.
....shiat...is that even the right spelling???


FAWK<<<<

getting old

[skrapgiarc]

I would love to have the tools/ability to do this. Very nice!

[aaronsb]

Ok, finally got ALL the major skin attached. It's not all riveted into place, but as I can wheedle my friends into holding a bucking bar competently I'll get the rest of the rivets in.

I still need to fill in the holes where the old flashing lights went.

I'm using a cold galvanizing zinc spray between the ribs and the sheet panels, hopefully that will keep down oxidization. I may end up just spraying the zinc coating all on the inside anyway, since it will eventually be trapped between insulation.

Once all the panels are enclosed, and I've got a relatively leak-free envelope, I'll start ripping up the flooring. I feel like I've been doing this backwards because everyone seems to tear the floors out first!

In the 3rd photo you can see the end flange I haven't trimmed it down properly yet so it sort of hangs off like a big ugly square...thing.
In the 4th photo I still haven't ground down some of the weld seams to flush, I just lightly dressed with the flap disc and covered with primer so things don't rust here in the pacific north-wet.
In the last photo, you can see how the panels lay with just a couple clecos holding things together. Once they're riveted it'll look a lot more like a "proper" bus shaped object. I'm pretty happy with the stance the bus has given the size of the wheels, and the height of the chassis.

Once everything's riveted in, I'll get that upgraded rain gutter/drip rail installed as well, and maybe get some better paint on the outside. It's just primer for now to keep things from turning brown (rusty).