NEED URGENT ADVISE;Weird wood placement between metal exterior pieces

[LivingDreamsHere]

Hello!
I just got my 1999 E-450 shuttle bus and began demoing the interior. I had to take out the windows temporarily to take out the wood that was being held in by it. I came across a really peculiar structural issue where there are wood pieces sandwiched between the exterior of the bus and the metal of the windows. I don’t know if it’s actually just a shell placed over the bus with wood on top of the metal frame. I want to take out the spray foam insulation that is there and reapply new insulation in the future. My question is: How should I go about handling the rust and reinstalling the windows and insulation with this issue?

[CHEESE_WAGON]

Looks like the walls are made of exterior-grade plywood, with basic insulation sandwiched between it and exteriorm/ interior paneling. IMO, not much you can do with that other than spray-foam the interior surface before adding an overlay panel.

[LivingDreamsHere]

Originally Posted by CHEESE_WAGON

Looks like the walls are made of exterior-grade plywood, with basic insulation sandwiched between it and exteriorm/ interior paneling. IMO, not much you can do with that other than spray-foam the interior surface before adding an overlay panel.

Thank you for your advise! Do you think the overlay panel should be made of metal or plywood as well?

[LivingDreamsHere]

Originally Posted by CHEESE_WAGON

Looks like the walls are made of exterior-grade plywood, with basic insulation sandwiched between it and exteriorm/ interior paneling. IMO, not much you can do with that other than spray-foam the interior surface before adding an overlay panel.

Thank you for your advise! Do you think the overlay panel should be made of plywood or metal sheets?

[CHEESE_WAGON]

I would use luan over 2x2 or 2x4 framing, myself. Would give you 2" of insulation on each wall.

[LivingDreamsHere]

Okay, great! That makes me feel a lot less overwhelmed at finding that today. Thank you so much for your help!!

[JackE]

The amount of rust on those framing pieces indicates a lot of moisture getting places it shouldn't. I would be willing to bet you have some roof seam leaking going on. The motor home I am tearing apart as donor for my bus looks like this in all the walls. It had/has serious roof leaking issues. You need to find and fix all the leaks before you start any inside work or it will soon be ruined too.

[LivingDreamsHere]

Originally Posted by JackE

The amount of rust on those framing pieces indicates a lot of moisture getting places it shouldn't. I would be willing to bet you have some roof seam leaking going on. The motor home I am tearing apart as donor for my bus looks like this in all the walls. It had/has serious roof leaking issues. You need to find and fix all the leaks before you start any inside work or it will soon be ruined too.

Yes, you're right. I saw a break in the middle seam that runs along the top of the bus. I ordered some tropicool roof sealant yesterday and I'm about to pick it up now after sealing the seams.Hopefully that'll do the job.

[leadsled01]

Check out Robert Branden shuttle bus on you tube. He used aluminium sheet metal to cover his windows. Looks nice.