Originally Posted by bender477
cut away rusted areas with a d/a, wirewheel surface rust away and paint all bare metal with rustolium, cut a steel patch to size, paint the patch both sides, line perimeter of hole to be patched with butyle tape, place patch over hole and drill screw holes ( use stainless steel screws only ) make sure to go all around the patch perimeter.
finish off by cleaning adjoining seams and apply butyle lapping caulk around seams and screws to weatherproof fully.
as for your other issue you could install auxillary coolant gauges or some type of "coolant level sensor " wired up to an idiot light , that way if a leak develops and coolant level drops you have an early warning before it overheats. many auto especially European have systems like this ( hint hint )
Thanks for the tip with the butyl tape. What do you think about using aluminum for patches rather than steel? My wife made thatsuggestion nad it could be good unless stress cracking is an issue. I was thinking of having sheet metal formed to mimic the gutter as the origina design (flaw) had the gutter 'j' mole under the roof panels. We will be having a ssheet metal guy take a look.
Here are a couple pix. The brow of the bus is rusted under bondo, so not too sure how to deal with that... (lots of bondo all around).