As suggested by Sean Zee Tattoo (facebook user that I discussed diamond shuttle bus rebuilding with) I also used 1708 fiberglass to re-attach the walls to the floor (2 layers). For the plywood I used marine grade 3/4" from Menards in St. Louis. I highly recommend marine grade over any kind of interior grade from home depot. For the 1708 I did two layers along the entire seam. It's important to pre-apply resin to the plywood, or it will soak it all up.
I purchased the fiberglass from
Fiberglass , Epoxy , Composites, Carbon Fiber - U.S. Composites, Inc.. They shipped it pretty quick, but the best part about buying from them (as opposed to amazon or some other place similar) is you can call them and talk to the engineers directly. Describe what you're doing and they'll talk you through any concerns and what you'll need.
All in all though, it's a pricey job. I think easily over a grand between the plywood and fiberglass, plus oscillating tool bits, wire wheels, etc for the demolition.
One of the things that eventually will be important it to locate and inspect the status of the wood boards that are built into the wall and ceiling , and or use them for mounting things or lifting the body of the bus to get the plywood in. I recommend using a stud finder to help locate where they are and importantly, where they are not.
For the windows, in addition to a double layer of butyl tape obtained from home depot, I tried two different products to seal around the exterior edges: Sikaflex-221 and DAP Dynaflex 230. The Sikaflex was recommended by Sean, but the DAP Dynaflex was recommended by some RV repair videos on youtube (
). The Dynaflex product is much easier to aplply and clean up, but it cracked within the first 72 hours post cure under the stress of bus movement, but the Sikaflex has continued to hold up very well.
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