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Old 06-06-2023, 07:57 AM   #1
Bus Nut
 
Join Date: Aug 2020
Location: Alabama
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Year: 1996
Coachwork: BlueBird
Chassis: International 3800
Engine: DT 466 Mech. Spicer 5 speed
Rated Cap: 34
Covering up windows

I have a 1996 Blue Bird dog nose short bus, and I would like to cover all the windows with metal, and then cut holes for RV windows. The Blue Birds have those eyebrows over the windows, and I am trying to figure out how to do this without making a mess of it.

Can someone point me to a write up or YouTube video of someone doing this, that you would approve of?

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Old 06-13-2023, 11:38 PM   #2
Skoolie
 
Join Date: Aug 2022
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Year: 2002
Coachwork: Bluebird
Chassis: All American
Engine: 8.3 Cummins
I'm in the middle of this now, I'm removing all of the rivets (with a rivet shaver) along the top of the bump rail (black on my bus) just below the the windows. Then I'm removing all of the rivets up the center rail which should be 6 or 2 rows of 3 rivets. I'll put the metal behind the top of the bump rail and then push it up as high as possible using those 2 rivets per window to hold it in place.

You can also make window inserts that go in from the inside but more room for leaking and not much time savings. For my windows I think I need a 25.5" piece of metal roughly 9.5 feet long.
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Old 06-14-2023, 12:27 AM   #3
Skoolie
 
Join Date: Jun 2021
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Lots of ways to cover the windows, here one way...
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I had some 1"x2" angles made in 14 gauge for the top and bottom. The deletes have 2 sides bent to attach onto the hat channels. Used plenty of Sikaflex 221 and they are really sealed well. Didn't need to remove any rivets to do it this way... I can make more photos if that will help you.


John T.
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Old 06-14-2023, 09:45 AM   #4
Skoolie
 
Join Date: Jun 2021
Location: Minnesota
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Year: 2003
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Chassis: International 3800
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Rated Cap: 77
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Had to notch out the angle iron on the top side. Getting the rivet gun onto the top rivets was complicated by the window "brows" on the top, just barely able to do. The deletes are 18 gauge.
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Old 06-14-2023, 11:10 AM   #5
Bus Nut
 
Join Date: Aug 2020
Location: Alabama
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Year: 1996
Coachwork: BlueBird
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Thanks for posting those photos. Two are worth 2000 words. Very helpful.

Jeffrey
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Old 06-14-2023, 09:58 PM   #6
Skoolie
 
Join Date: Jun 2021
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Engine: DT466e 215hp Allison 2500
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No worries Jeffrey.
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One thing I'd do different is make the angle a 2.25" (a little longer) so riveting under the brow would have been easier.



I chose to install the delete tight on top, and 1/2" short on the bottom. I cleaned off the excess sealer immediately, going to run a 1/4" bead of sikaflex around all joints to finish the chore off.



Instead of trying to make tight fitting delete panels I made them a 1/4" smaller, only used rivets on one side, went back and used wedges, sealer and self tappers one the opposite side.
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Old 06-17-2023, 05:38 PM   #7
Skoolie
 
Join Date: Dec 2019
Location: Union Bridge Maryland
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I had sheet metal man make me a piece of trim that covered the window eyebrows . I cut rivet head with wafer wheel, then air chisel with small vee cut into center. Started lower rivets,they get covered up. Then upper after practised on lower. Still had a little spot puddyMy large bus i drilled out most. Built scaffold bougjt 40 bits,6 cases of beer. Invited everyone i knew. Went pretty fast,one side anyway.
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Old 06-17-2023, 06:12 PM   #8
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I wish that there was a “Thank You” button, because brother, I really appreciate this! ��������
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Old 06-17-2023, 10:32 PM   #9
Skoolie
 
Join Date: Dec 2019
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Those joints where all the metal meets, if you spray it on the inside with "Truck Bed Liner" it helps to guarantee it will never leak. Thats great idea the upper angle . Got me rethinking things
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