This shuttle bus has nothing below the plywood, except in the small area of the cab there is the cab sheetmetal, but the box has just plywood. Mine looks in good shape.
I am keeping the fiberglass outer layer, replacing the honeycomb with foam insulation and the inner layer will be thin plywood, all epoxied together. I am debating whether to remove all the good honeycomb on the drivers side or leave it. As you know, the bus is full of windows, so there really isn't much wall at all, except maybe 2ft or so at the bottom. I will be re-using the ceiling fiberglass sheet for the outer layer of fiberglass. It is a bit thin, but good enough. I have a bunch of 1 inch 4x8 sheets of polyiso removed from my old office ceiling which I will use, but I really want 2 inches, so would have to double them up, so maybe I have to actually spend some money and buy some 2inch polyiso, stuff is not cheap when so far I've got about $200 in this project.
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