Windows: To weld (or rivet) or not to weld??

[GoneCamping]

I covered right over the windows on my unit, left them right there in place. Covered them on both sides except where I wanted some RV style windows, I removed the old windows and created larger openings and installed the new windows. If you can get someone to weld sheet metal over them I'd go for it!!

[paul iossi]

the heat of welding may cause warping of the sheetmetal and or issues with the existing adhesive/sealants used in initial construction of the bus. try itand let us know how it works out.

[timbuk]

dont think id weld in a bunch of panels to close windows.Bus mdoes not need that extra strengh and will remove the flexibility the body gets with rivits and bolts and screws.Dont kid yourself that bus flexes more than you think..you dont want to eliminate that!

[timbuk]

this old bus was skinned with aluminum that looked like wood and insuled with wood mbacking i put on the black roofing panels not saying how to do it but thats what i did plus i drank beer while doing it and the roofing was free.wish the beer was timbuk

[RazorCityDen]

I used individual 20 gauge sheet metal inserts, they went in nice and tight and have sealed well, you can check pictures out on the Conversion Projects page. So did Sporty Rick which is where I got the idea, he's got some pictures as well.

Den,

[Papabear]

IMHO, If I were going to weld the side skins in, I would go with thicker sheet metal. 18 or even 16ga. You'll get a lot less warping and easier to stich weld and grind down.
I went with 20 ga. and rivits because:
1. I'm working by myself
2. To weld, I would have to bring the jenny and welder to the storage yard, then take them home everynight.
3. My air snippers would not cut 16 ga.
4. It was the most covert way to skin the sides (My wife still don't know about this project )
Note. I did not put rivets on one inch centers, just to much overkill.