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Old 06-22-2021, 06:28 PM   #1
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Best Way to Fill the Emergency Exit

Hello Fellow Skoolies, I'm working on a fiberglass 15 passenger shuttle bus and was wondering what this group thought would be the best way to fill the opening where the roof emergency exit was removed. The opening is 29" X 29". I'm considering a polycarbonate sheet like Lexan, aluminum sheet, fiberglass sheet or making my own poor man's fiberglass panel. In the future I'll be using the opening to install a roof mount RV air conditioner. Of course, I'd like a soluition that will last many years (5-10, if possible). All these choices except the poor man's fiberglass seem fairly expensive. What do you think would be the best material to use? Thanks for any input you might have.



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Old 06-22-2021, 06:33 PM   #2
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The best way would be to keep the emergency exit ...
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Old 06-29-2021, 07:21 AM   #3
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One way would be to remove the exit and to put a metal panel on the roof with a sealant under it and screw, pop rivet it down. Or weld it in place ( a better option) then when your ready ( if ever) to add the AC, put it in a different place.
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Old 06-29-2021, 08:33 AM   #4
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You can rivet a steel (or AL) patch through the fiberglass. Maybe one with the standard 14" sq (14-3/16") hole, so you can swap out any rv accessory you choose.

Use a backer strip or washers on the inside so the fiberglass is squeezed between. Optionally, you may use epoxy on each rivet as you set them. Same on the backer strip.
A wide overlap will add rigidity to the assembly.

Many light aircraft manufacturers rivet fiberglass cowling nose bowls, fiberglass landing light mounts to AL, piano hinges to fiberglass... often using rivets and washers or backer plate.
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