Shuttle Bus Roof is Toast

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So we bought a shuttle bus and realized after getting it home that the roof is completely shot. Previous owner said the emergency hatch was leaking and they did a half butt job in sealing. As we removed the hatch we realized it has either been a little leak for a LONG time or simply a much larger leak and we got duped. We cut it back until it was dry and now here we are owners of a 2014 E450 shuttle bus that has no roof. We are thinking of plywood "ribs" to get the curve we need with a layer of 1/4" sheet on top then fiberglass on top of that. Foam insulation in between "ribs" and plywood underneath. Has anyone ever rebuilt/replaced a roof on a shuttle? Is this a decent plan?
 
Welcome!

Sorry you have a project that you didn't plan on. A couple of pictures would help the conversation and inform the advice. I think you have to post 5 times before you can add any.
 
if you can weld you can buy 18ga steel sheets, and build a new roof like that.

Do it soon before steel prices go up.
 
Unfortunately this whole thing is fiberglass, there was a 2x4 runner that ran the full length of the bus sandwiched in between fiberglass with honeycomb filling the void. The fact the 2x4 were run length wise I assume is the reason the roof structure fell once wet.
 

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oh ok, all fiber glass. Sorry to hear. Yeah that's gonna be a project. maybe a loss unless you can find a way to join fiber to metal.
 
Definitely a project but our plan is to give some structure with 4" wide plywood ribs with a sheet of plywood ontop then covering the whole thing in fiberglass. Definitely cannot call it a loss at this point too far down the road to turn back now lol.
 
I do think your plan is a good one. I have built many boats, mostly wood/composite. I use epoxy resin with fiberglass cloth. System Three is the brand I use, and has done well for me, with over 25 years of boat building. They do have a good handbook on working with their epoxies for those not too familier with it.
 
Big project but gives you an opportunity to add some clerestory lighting.

Shuttles have lots of headroom, which helps when designing trusses or whatever.

I seem to remember someone else who had sagging fiberglass composite roof. They either talked about plywood laminate 'beams' or showed a few pictures.

Keep us posted.
 
You've got a project alright.

IMO - step one is to decide what net shape you want to end up with. If there's enough headroom without going up farther, then maybe recreating the inner roof contour is your goal. If you want more headroom or skylights, then you have to design that first.

Front to back - how long is the opening?

+1 on System 3 or West System. I've used the latter for a long time, but I think the brand doesn't matter. West also has a technical guide which is very detailed. It's geared towards boatbuilding, but that's essentially what you've got - an upside down boat hull.

If I was recreating the inner roofline I'd do something like this:

Find some structural fiberglass to make up for the missing 2x4s. I'd start with channel or tube sections that best matched the thickness of the core. No harm in having more than what was there originally. I'd start with three anyway. Here's an idea, match the 'leg' height to your core material.

https://www.grainger.com/product/FIBERGRATE-Fiberglass-U-Channel-3-in-4ATN2? If this isn't long enough, there are plenty of other sources. You could even use 2x4s again but I'd want to do something stiffer and inorganic. As in boats, any deck penetration is a potential water leak and core degradation.

Then I'd scoop out at least 3" of core all around. They do this in boat building when fixing cored decks - get back to clean, dry materials.

I'd put the channels in with epoxy. Stuff the ends into the core area front and back, legs down. Maybe right next to the original 2x4s or what ever is there. Add some thickener to make it like smooth peanut butter. They sell this but really fine sawdust works just as well. Butter it thickly - weight doesn't count against you - you're not building an airplane.

Then, from bottom up, take some composite fiberglass sheeting like they use for shower surrounds and build the skin. Sand roughly where gluing. Use temporary springers to hold the shape while gluing. Put fillets on the top where the skin meets the channels with more peanut butter. Glass over with 3" fiberglass tape.

With two or more overlapping layers of skin (build up to approx original thickness), add foam panels to match/replace the core. Stuff the foam into the core areas to tie it together.

Once it's skinned and cored, apply the outer skin same as the inner.

One last thing - epoxy is more expensive, but reliably bonds to more things than polyester. Polyester resins used for automotive use styrene in the catalyst, and that will eat most foam products. If you can paper mache, you can fiberglass. Use plenty of PPE - long term exposure to the hardener will result in allergies.
 
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