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Old 09-03-2019, 09:02 AM   #41
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Join Date: Sep 2014
Location: Eustis FLORIDA
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Year: 1999
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Chassis: Freighliner FS65
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I wonder why- didn't he make his own?
They're pretty easy to do if you have a brake.

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Old 09-03-2019, 09:42 AM   #42
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Join Date: Jun 2015
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Year: 1999
Coachwork: American Cargo 14'L x 7'8"W x 7'H Box
Chassis: Ford E350 Cutaway
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Originally Posted by EastCoastCB View Post
I wonder why- didn't he make his own?
They're pretty easy to do if you have a brake.
I guess that for him being on the road it is easier to order these things.
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Old 12-07-2021, 09:39 AM   #43
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Year: 1998
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Originally Posted by EastCoastCB View Post
No sq tubing would fit mine worth a DAMN.
Would you have used square tubing instead? I was gonna start a thread asking the difference between or preference of tubing or hat channel. Does one benefit over the other? Is one stronger?

Thanks
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Old 12-07-2021, 10:11 AM   #44
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Would you have used square tubing instead? I was gonna start a thread asking the difference between or preference of tubing or hat channel. Does one benefit over the other? Is one stronger?

Thanks
I'd go square tubing if it fit perfectly like a glove. Otherwise a custom channel to fit what you have is the best.
Square tubing properly fit should be stronger. But I'd not do what others have and use undersized square tubing with shims.
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Old 12-29-2021, 04:08 PM   #45
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Year: 2005
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Chassis: Saf-T-Liner HDX
Engine: Cat C7 7.3L
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My 05' Thomas HDX hat channels had an ID of 1-1/8th" so I bought heavy 1" square tubing and 1/8" flat stock. I tacked the flat stock to one side of the heavy square tube and clamped it into my channels.

I made sure that my square tube was long enough to be below the rub rail on the bottom by several inches where possible. (Some of my hat channels had existing lengths of tubing that prevented this and I butt welded my square tube to it in this case.) On the top I mad sure my square tube was up above/inside the roof line so if any one of my stations came loose it would be sandwiched by multiple layers of steel and wouldn't totally fail. Also gave me ALOT more surface to weld too. I have about 7 pounds of .035 wire tied up just in my stations. I then panel bonded and screwed my 16ga sheet to the hat channels, the roof line and top of my rub rail. My bus is 40' and I used 160 ft of square tube, 13x 4x8 sheets to skin the whole bus 9 total for the sides and three for the back and front transition, which I just finished installing today.

I have some pictures if you want 'em. I only post pictures here when necessary as it's a serious PITA.
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Old 12-29-2021, 06:26 PM   #46
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I used square tubing and overlapped at least 6, top and bottom. Then I performed so of my magical popcorn welding!
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Old 12-30-2021, 03:33 PM   #47
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Originally Posted by enigmamdw View Post
My 05' Thomas HDX hat channels had an ID of 1-1/8th" so I bought heavy 1" square tubing and 1/8" flat stock. I tacked the flat stock to one side of the heavy square tube and clamped it into my channels.

I made sure that my square tube was long enough to be below the rub rail on the bottom by several inches where possible. (Some of my hat channels had existing lengths of tubing that prevented this and I butt welded my square tube to it in this case.) On the top I mad sure my square tube was up above/inside the roof line so if any one of my stations came loose it would be sandwiched by multiple layers of steel and wouldn't totally fail. Also gave me ALOT more surface to weld too. I have about 7 pounds of .035 wire tied up just in my stations. I then panel bonded and screwed my 16ga sheet to the hat channels, the roof line and top of my rub rail. My bus is 40' and I used 160 ft of square tube, 13x 4x8 sheets to skin the whole bus 9 total for the sides and three for the back and front transition, which I just finished installing today.

I have some pictures if you want 'em. I only post pictures here when necessary as it's a serious PITA.
I'd like to see pics, please!
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Old 12-30-2021, 03:50 PM   #48
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I'd like to see pics, please!
I haven't seen Enigma's pics, but it sounds like we use similar materials. We get suitable square tube and use it in conjunction with 1/8x3" flat bar, which we bend to form radiused sides. I think we show that in this video: https://youtu.be/um_V8CoInz0
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