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Old 10-14-2017, 02:52 PM   #21
Bus Nut
 
Join Date: Jul 2017
Posts: 570
Year: 1993
Coachwork: Goshen
Chassis: E350
Engine: 7.3 IDI
Rated Cap: 14
Finished sealing the seams. Supposed to rain tomorrow so I'll know if there are any problem areas. My butyl tape came in today. Going to wait a week or so for the sealant to fully cure.. then re-install the gutters with the tape and screws.

Gonna pick up insulation for the walls and floor tonight along with plywood for the subfloor.

If all goes well, should have it ready to start building cabinets and such by mid next week.

Also ordered a few odds and ends for mechanical fixes. Ordered an injector return line kit (return caps, viton o-rings, hoses, olive seals).. valve cover gaskets and oil cooler gaskets. Valve covers are leaking a bit.. oil cooler isn't but with age, they are a common leak spot. Its an easy fix so might as well do it before it fails.

Will also be pulling the radiator and test fitting a 4 row aluminum unit built by Champion radiators. I run one in my 1990 F350 and love it. They don't offer one for the van chassis... but the only difference is the lower mounts. I'll build some mounts using the old truck radiator I've got.. then get one ordered. It currently has a plastic parts store replacement (all of those are only 2 row when the factory is 3.. and they are prone to failure in these for some reason). Then I'll be going through brakes and wheel bearings front and back...

I also plan to drop the rear driveshaft and have it rebuilt (new spicer joints and carrier bearing and rebalance). While having that done, I'm going to drop the trans pan and install a Transgo shift kit and upgrade the cooler to a Longs Trucool 40k. The transmission in the bus is a reman unit with only 80-90k on it.. Want it to last a good long while.

Anyways... more to come as work progresses.

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Old 10-14-2017, 05:41 PM   #22
Traveling
 
Join Date: Nov 2015
Location: Midwest
Posts: 2,573
Year: 2003
Coachwork: BlueBird
Chassis: TC2000
Engine: 5.9L Cummins
Rated Cap: '00
Quote:
Originally Posted by Mr4btTahoe View Post
Finished sealing the seams. Supposed to rain tomorrow so I'll know if there are any problem areas. My butyl tape came in today. Going to wait a week or so for the sealant to fully cure.. then re-install the gutters with the tape and screws.

Gonna pick up insulation for the walls and floor tonight along with plywood for the subfloor.

If all goes well, should have it ready to start building cabinets and such by mid next week.

Also ordered a few odds and ends for mechanical fixes. Ordered an injector return line kit (return caps, viton o-rings, hoses, olive seals).. valve cover gaskets and oil cooler gaskets. Valve covers are leaking a bit.. oil cooler isn't but with age, they are a common leak spot. Its an easy fix so might as well do it before it fails.

Will also be pulling the radiator and test fitting a 4 row aluminum unit built by Champion radiators. I run one in my 1990 F350 and love it. They don't offer one for the van chassis... but the only difference is the lower mounts. I'll build some mounts using the old truck radiator I've got.. then get one ordered. It currently has a plastic parts store replacement (all of those are only 2 row when the factory is 3.. and they are prone to failure in these for some reason). Then I'll be going through brakes and wheel bearings front and back...

I also plan to drop the rear driveshaft and have it rebuilt (new spicer joints and carrier bearing and rebalance). While having that done, I'm going to drop the trans pan and install a Transgo shift kit and upgrade the cooler to a Longs Trucool 40k. The transmission in the bus is a reman unit with only 80-90k on it.. Want it to last a good long while.

Anyways... more to come as work progresses.
We expect all that to be done by Monday, at the latest.

Have you ever worked at a job and there is one guy who works 5-times as hard and as fast as everyone else, thereby making the 'normal' people look bad???

I've had my bus since January and the interior is still empty.
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Old 10-14-2017, 05:47 PM   #23
Bus Nut
 
Join Date: Jul 2017
Posts: 570
Year: 1993
Coachwork: Goshen
Chassis: E350
Engine: 7.3 IDI
Rated Cap: 14
I'm just really motivated to get it done. That.. and the wife is motivated for it to be done too... so its a project that I like working on... that she doesn't have an issue with me spending some time and money on. Lol

It wont be usable til next spring. Just trying to get the inside insulated so work can continue through the cold months.

A friend of mine will be building the cabinets and such so once I get this stuff done, its on him. I've been trading work with him for a good bit.. now it's time for me to collect.

The mechanical bits are pretty simple... and that's my side. I'm no carpenter but I can turn wrenches for days.
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Old 10-14-2017, 06:19 PM   #24
Bus Geek
 
Join Date: May 2009
Location: Columbus Ohio
Posts: 14,858
Year: 1991
Coachwork: Carpenter
Chassis: International 3800
Engine: DTA360 / MT643
Rated Cap: 7 Row Handicap
Quote:
Originally Posted by Mr4btTahoe View Post
I'm just really motivated to get it done. That.. and the wife is motivated for it to be done too... so its a project that I like working on... that she doesn't have an issue with me spending some time and money on. Lol

It wont be usable til next spring. Just trying to get the inside insulated so work can continue through the cold months.

A friend of mine will be building the cabinets and such so once I get this stuff done, its on him. I've been trading work with him for a good bit.. now it's time for me to collect.

The mechanical bits are pretty simple... and that's my side. I'm no carpenter but I can turn wrenches for days.

thats me!! im HAPPY turning wrenches.. but hand me wood and a table saw and im like " do i cut this in firewood length pieces?"

-Christopher
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Old 10-14-2017, 06:21 PM   #25
Skoolie
 
Join Date: May 2017
Location: Lake geneva Wisconsin
Posts: 199
Year: 93
Coachwork: Amtran
Chassis: International
Engine: 7.3 idi
I'd trade woodwork for computer anyday
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Old 10-14-2017, 07:02 PM   #26
Traveling
 
Join Date: Nov 2015
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Quote:
Originally Posted by Greatestrr View Post
I'd trade woodwork for computer anyday
I like both- at the same time. There is nothing like teaching a computer-controlled router to do your work. I used to run a cnc mill in a hi-end cabinet shop- it was a blast. I was i the best shape of my life- slinging 3/4 sheets alone all day.

I'd cut all the cabinet sides on my machine, then do the hard stuff- curved moldings, exotic mullions, templates for the shaper guys. Really taught me to see in 3-D. I still have cnc router, only 2.5 axis, but have the Gecko for full 4-axis. Running Mach3, do my layout in Adobe Illustrator, bounce around to get G-code.
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Old 10-15-2017, 12:12 AM   #27
Bus Nut
 
Join Date: Jul 2017
Posts: 570
Year: 1993
Coachwork: Goshen
Chassis: E350
Engine: 7.3 IDI
Rated Cap: 14
Here is another part of the reason why I'm motivated....

IMG_20171014_210403157 by acidburn02zts, on Flickr

My shop is crammed full at the moment.. and since I turn wrenches on the side of my full time job and my work space is full... somethings gotta give.

Anyways... Ready for the rain!
IMG_20171014_225622277 by acidburn02zts, on Flickr

You can see one of my makeshift transfer tanks I'll be using. One of the biggest parts of this project is running on alternative fuel and having a long range doing it. I'll be using 2 55 gallon drums placed in the same spot on each side. One will be under the main bed and one will be under a bench. This is when I wish the bus was a real bus so I'd have space under it for things like this.. but oh well. The fuel that will be in them isn't flamable and the drums will be mounted very securely and supported evenly. I plan on contouring some 2x8s (3 or 4 per drum) that will support the weight evenly. Should work out... we'll see.

Going to trim out 6" of the wheel well (plenty of space under the bus for it. Tires will have plenty of room.) and move the drums towards the rear a bit further. This will put all the weight just forward of the axle.

IMG_20171014_224245315 by acidburn02zts, on Flickr

The real fun begins once the rain comes and I dont see any leaks. If it doesnt rain much tomorrow, I'll get up on the roof with the hose and do it that way.

More to come.
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Old 10-15-2017, 10:51 AM   #28
Bus Nut
 
Join Date: Jul 2017
Posts: 570
Year: 1993
Coachwork: Goshen
Chassis: E350
Engine: 7.3 IDI
Rated Cap: 14
Verdict is in...

No more main seam leak. Ive got 2 windows leaking slightly but they have to come out anyways to install the new paneling... so they are all getting resealed. Now I've got work to do.
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Old 10-15-2017, 01:38 PM   #29
Bus Nut
 
Join Date: Jul 2017
Posts: 570
Year: 1993
Coachwork: Goshen
Chassis: E350
Engine: 7.3 IDI
Rated Cap: 14
Progress is good...

Floor rot repair...
IMG_20171015_121750513 by acidburn02zts, on Flickr

IMG_20171015_122754741 by acidburn02zts, on Flickr

IMG_20171015_124651380_HDR by acidburn02zts, on Flickr

Mucho better. After raining all morning, found one small spot near the roof seam that was damp. Got that fixed (small pinhole in sealant). Now that I know the sealant has stopped the leaks.. I'll feel even better once sealed over with Butyl tape and the gutter back in place.

IMG_20171015_121759241 by acidburn02zts, on Flickr

Now onto insulation... Using 3/4 XPS in the walls leaving a 1/4" air gap. Gives a better performance rating then stuffing the walls full with 1".

IMG_20171015_130139599_HDR by acidburn02zts, on Flickr

IMG_20171015_131039588_HDR by acidburn02zts, on Flickr

The boy is up from his nap so I'm back in the house for a bit until the wife gets home here in a bit... then back at it.
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Old 10-15-2017, 02:14 PM   #30
Bus Crazy
 
Jolly Roger bus 223's Avatar
 
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Location: Swansboro,NC
Posts: 1,660
Year: 86
Coachwork: Thomas
Chassis: Ford B700
Engine: 8.2
Rated Cap: 60 bodies
Quote:
Originally Posted by Mr4btTahoe View Post
Verdict is in...

No more main seam leak. Ive got 2 windows leaking slightly but they have to come out anyways to install the new paneling... so they are all getting resealed. Now I've got work to do.
When gutted
I put a couple of sprinklers on my roof and let them spray while I was away and chase leaks when I got home. Ended up sealing all of the windows just cause more were leaking than not.
Good luck
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Old 10-15-2017, 03:01 PM   #31
Traveling
 
Join Date: Nov 2015
Location: Midwest
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Coachwork: BlueBird
Chassis: TC2000
Engine: 5.9L Cummins
Rated Cap: '00
Quote:
Originally Posted by Mr4btTahoe View Post
Progress is good...



The boy is up from his nap so I'm back in the house for a bit until the wife gets home here in a bit... then back at it.
Scrub that wall/floor with bleach water to kill mold. I'd paint that inner wall with Kilz or something to protect.
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Old 10-15-2017, 03:59 PM   #32
Bus Nut
 
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Originally Posted by Rusty View Post
Scrub that wall/floor with bleach water to kill mold. I'd paint that inner wall with Kilz or something to protect.
Hmm... I probably should have thought about that a bit sooner. I new I was forgetting something. I had planned on spraying down the interior with bleach water and letting it dry out before going any further... but I skipped it by accident. I haven't seen any mold or signs of mold other then on the exterior... mostly just water stains/rot.

I'll probably go out and spray down the rest of the exposed walls floor with the solution before going any further. Hopefully it wont cause an issue later.

IMG_20171015_152139992_HDR by acidburn02zts, on Flickr

IMG_20171015_152128546_HDR by acidburn02zts, on Flickr

Was going to finish insulating tonight... but I suppose some mold prevention would be a better idea. No point in rushing I suppose.

On another note, the subfloor that is down so far is solid and the insulation is already making a difference in interior noise and temperature.
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Old 10-16-2017, 12:50 PM   #33
Bus Nut
 
Join Date: Jul 2017
Posts: 570
Year: 1993
Coachwork: Goshen
Chassis: E350
Engine: 7.3 IDI
Rated Cap: 14
Had a little free time at work this morning so I bent a couple patch panels for notching the wheel humps. I'm cutting 6" out of the front of them which will give me room to push my fuel tanks back closer to the rear axle and give me the space I need in front. Hope to get these in tonight so I can get the floor finished.

IMG_20171016_114001923 by acidburn02zts, on Flickr
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Old 10-16-2017, 01:30 PM   #34
Traveling
 
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Rated Cap: '00
Quote:
Originally Posted by Mr4btTahoe View Post
Had a little free time at work this morning so I bent a couple patch panels for notching the wheel humps. I'm cutting 6" out of the front of them which will give me room to push my fuel tanks back closer to the rear axle and give me the space I need in front. Hope to get these in tonight so I can get the floor finished.
I don't need to remind you to check the full suspension travel, especially with the 2 drums of used 10w-30 you'll be burning. Maybe air-bag helpers?
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Old 10-16-2017, 01:41 PM   #35
Bus Nut
 
Join Date: Jul 2017
Posts: 570
Year: 1993
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Chassis: E350
Engine: 7.3 IDI
Rated Cap: 14
Quote:
Originally Posted by Rusty View Post
I don't need to remind you to check the full suspension travel, especially with the 2 drums of used 10w-30 you'll be burning. Maybe air-bag helpers?

I took some measurements before considering this and the wheel humps are a good 4" above the body cutouts for the tires... meaning if the suspension compresses that far, it will destroy the body and tires long before it gets into the wheel tubs.

With that said, once I get it loaded out and all the tanks full.. I'm going to see how it sits on flat ground. If it is sitting nose high, I'll go with airbags for sure.
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Old 10-16-2017, 10:37 PM   #36
Bus Nut
 
Join Date: Jul 2017
Posts: 570
Year: 1993
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Chassis: E350
Engine: 7.3 IDI
Rated Cap: 14
Chop Chop....

IMG_20171016_173420275 by acidburn02zts, on Flickr

Not the best work I've ever done... but didnt have enough material laying around to just build new tubs. So.. patch it up... seal it up... and undercoated from the under side to help prevent future rot.

IMG_20171016_220604730 by acidburn02zts, on Flickr

I gained 6" of space (which doesn't sound like much..).. but it allows me to push my fuel drums back 6". On this side.. it isn't as important.. just wanted the position of the tanks to match side to side. On the other side, it will gain me room to add another storage cabinet just forward of the bench that will be hiding the tank.

Anyways.. I'll do the other side tomorrow night.. then sort out the drum mounts... then finish up the subfloor and insulation.
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Old 10-18-2017, 08:44 AM   #37
Bus Nut
 
Join Date: Jul 2017
Posts: 570
Year: 1993
Coachwork: Goshen
Chassis: E350
Engine: 7.3 IDI
Rated Cap: 14
Both wheel tubs are done. On to finishing insulation and the subfloor.

I called my buddy who is doing my cabinets and beds and he said he is ready to get going on everything as soon as I'm done with the floor and walls.

Cant wait!!
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Old 10-18-2017, 10:59 PM   #38
Bus Nut
 
Join Date: Jul 2017
Posts: 570
Year: 1993
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Chassis: E350
Engine: 7.3 IDI
Rated Cap: 14
More progress... Only a little more subfloor to go. Have a few things to work around and hopefully I've got enough 5/8 ply left to scab it together. We'll see.

I'll finish insulation tomorrow night and shoot for paneling and resealing windows over the weekend. Next week, cabinets get started on

IMG_20171018_223228910 by acidburn02zts, on Flickr

IMG_20171018_223243289 by acidburn02zts, on Flickr

IMG_20171018_223249318 by acidburn02zts, on Flickr

If I can swing it, I'm going to order some brake parts next month and see if I can get that knocked out before the weather turns.
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Old 10-19-2017, 10:51 PM   #39
Bus Nut
 
Join Date: Jul 2017
Posts: 570
Year: 1993
Coachwork: Goshen
Chassis: E350
Engine: 7.3 IDI
Rated Cap: 14
Insulation on the driver's side is done and the first wall skin is cut and up. Waiting to do the rest of the wall skins until I can pull the windows which will probably be Saturday.

IMG_20171019_215149856 by acidburn02zts, on Flickr

IMG_20171019_215142067 by acidburn02zts, on Flickr

IMG_20171019_222026272 by acidburn02zts, on Flickr

The water marks on the paneling were on it when I got it (reason it was free). I'll be painting all of it anyways so no worries.

Hope you guys don't mind a lot of pics... I take pictures of EVERYTHING.. lol

Anyways.. taking a break tomorrow night more then likely... then back to the wall skins on saturday.
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Old 10-21-2017, 07:20 PM   #40
Bus Nut
 
Join Date: Jul 2017
Posts: 570
Year: 1993
Coachwork: Goshen
Chassis: E350
Engine: 7.3 IDI
Rated Cap: 14
Slowly but surely. Windows coming out...

IMG_20171021_145300256 by acidburn02zts, on Flickr

IMG_20171021_145307248 by acidburn02zts, on Flickr

All out... skins cut and up

IMG_20171021_155621101 by acidburn02zts, on Flickr

Windows going back in with 3/4" butyl tape
IMG_20171021_163242421 by acidburn02zts, on Flickr

Looks like a good seal to me...
IMG_20171021_163335312 by acidburn02zts, on Flickr

My bus helper for the afternoon...

IMG_20171021_170211008 by acidburn02zts, on Flickr

All back together...
IMG_20171021_175616968 by acidburn02zts, on Flickr

IMG_20171021_175632087_HDR by acidburn02zts, on Flickr

Most of the windows had very degraded foam weather stripping for a gasket. They had been removed by the previous owner and stuffed with clear silicone which didn't stick to the fiberglass at all. I'd say this will hold up good.. but I'm going to go around the edge of each window with some through the roof as well just to make sure.

Driver's side is all but done... just need to button up the passenger side which should be pretty easy. We'll see.
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