Pic-less, boring, mod history thread, 10speed Thomas

Mr P

1996 International 3800. dt466. Meritor 10 speed
Joined
Dec 13, 2024
Posts
1,015
Location
Kentucky
If one guideline for this section is "a diary for your bus", here goes.

How I got a bus: In 2020 I noticed all the schoolies passing through. I thought about it for my (larger than most) family to see "the west". Being a car mechanic I knew the reliability of the 12v Cummins, and I think it was here that I learned about the DT466 being (possibly) a step better. I would occasionally search the net for a dt466 bus, then wait months before searching some more. Any dt466 bus I found would be several hours away, and I wasn't going to drive hours to "kick the tires". About a year ago I found one fairly close, and actually chatted with God about the situation, as it seemed like a nearly perfect location, price, and condition. Only....that bus was sold before I could even communicate with the seller. In a little "frustration", I prayed like "but this seemed good, but....what's next".

Because that local bus disappeared, I looked at the two remaining. The farther away was about 20 miles from where a good friend lived when I last saw him 20 years ago. I mistakeny sent my friend a FB message with ONLY a link to the bus advertisement, he replied with "I think I know where this bus is. I think it's in this town. I think that's the bus at the church I used to attend. Want me to go look at it for you?"

And he did. He actually had done much work driving trucks with dt466 engines, so he knew all about the engine, and gave me a good, factual report about the engine, bus condition, and performance. I got to spend time with that friend when I went to verify what he said and buy the bus. And got to spent some time with him and that church's pastor, it was a great time of reconnection for them. We sorta counted the "unusual" situations that all came together for that evening's meeting to occur.


The long trip home convinced me that the at545 needed to be replaced. FB Marketplace again...showed a semi trans for sale locally, sold by a former customer of mine. We reconnected, he said it was a good one. Thanks in part to answers from Caddilackid on this site, I figured out what I needed to put it in the bus.
 
Now to what I've got:

It's a 1996 International Thomas 3800, with wheelchair lift just behind the folding door. I suppose that because it's a handy bus, the floor is spaced up above the frame rails by about 5.25". And the floor had 4 seat mounting tracks from front to back, with a bolt every 4". There is a little rust over the rear wheels that's through the floor.

So total mods currently are:

10 speed and clutch pedals
removal of all floor
" of lift (300+- pounds of sheet metal (turning that into storage boxes, I hope)
" of about 14 feet of sheet metal "box" under the rear, probably held a ramp at one point.
" of all windows (after discovering how bad windows leaked, it's roof raise/rv window time)
" of 95% of all rivits
Cutting of some of the "hard cuts" at front and back

Edit to add:

Removed both factory AC condensers and evaporators, and a lot of hose
" seats of course
" most windows, keeping some near driver seat to keep stuff dry
 
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Aproximate expenditures: (ouch, this will hurt)

$4600 = bus and travel expenses
$2500 = trans, clutch kit, pedals, custom driveshaft, ect
$150 = RV toilet to measure and plan
$400 = Sunivora 5000w 12v inverter
$200 = 4 barrels and valves, seals, adapters for dirty water
$100 = Vevor diesel heater. Heated the bus a few times this winter, seemed to work well.
 
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That's really cool that you put in that 10 speed yourself. Maybe you could share in a thread how you did t so others could get inspired ...
I myself bought my "9906" bus in Louisville Ky. from the publicsurplus auction site. It was a relist, the first buyer did not pick it up.
60 miles into the ride home, 4:30 Friday afternoon, the oil lamp and alarm go off and I knew NOTHING about diesels.
I learned real quick about the HEUI system and what happens when you run out of oil, engine shuts down. Well mine never did so I cut the wire on the alarm and drove a green algae laden school bus all the way down to Miami!
I can really relate when you say "I talked with god"!
Thanks to all on this site I no longer "fear" breaking down on my bus so , I thank you all for the help and knowledge!

Post some pics of your bus, let's see what you got!
 
Aproximate expenditures: (ouch, this will hurt)

$4600 = bus and travel expenses
$2500 = trans, clutch kit, pedals, custom driveshaft, ect
$150 = RV toilet to measure and plan
$400 = Sunivora 5000w 12v inverter
$200 = 4 barrels and valves, seals, adapters for dirty water
Ah money, spend it on the wife and kids ... OR...buy a bus and tell the wife you'll be back in a few minutes!
 
So I remember a while back you were looking for electrical manuals. I have not been able to source one...yet but i did come across this from International, a print on demand.

I share this in hopes that with at least a manual number, well at least you know what to look for.

1753240430432.png
 
@ewo1 I used your navistar americommerce site, and modified the URL to show the whole list of manuals, and on the last page it had my manual for 1994-1996. Bought it for $32 on eBay.
It's CTS-5190
Feb1994-1996 Electrical Chassis

There's one left for $39.99 now for anyone with a 94-96 3-box bus.

And also through searching, not on there but on ebay, I did find a single copy of 1991-1993 electrical for $19. I bought that one as well. It was the only copy I saw. It didn't have a CTS number it's so old.
1991-93 Electrical Chassis.

None left I could find at time of this post, but if anyone needs any info from those year buses, I now own the electrical service manual.
 
In the search for a pinion mounted parking brake, I found some buses being scrapped. Under body boxes = $50 each. It took all afternoon to get two cut....more later?
 
I have removed storage boxes AND a pinion parking brake that *might* be adaptable to my axle, plus some fuel doors and battery box doors, all for $360. And $2.3 million in my labor.
 
I need to update parts prices....

5 gallons of liquid rubber $350?
bolts 20


The roof is raised.....the top is floating 12" higher now with only a few connections welded in. It's nice to walk without stooping.
 
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Congrats. You finally got it done. It is SOO nice to not have to bend down now!

We do need pics of it btw.
 
Oh, metal...$800

6 sheets of 20 gauge steel were about $430 of the 800
various angle and sqaure made up the remainder


Covered the hole in the floor where the lift used to be, HVAC will go under it.
 
I haven't done a word-count yet of your build thread, but I'm guessing it's likely under 1000 thus-far.

Just one picture... :giggle:
 

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