Subfloor much worse than we expected

[Ajayblohm]

So we finally went and picked up our bus. We were working on demoing this weekend and pulled up part of the floor to find that the she has a lot more rusting underneath than we had expected. We stopped pulling up flooring after finding this because if the rest of the bus is like this then it would make it dangerous to walk around in. I'm assuming that this is a case of "cut it all out and replace it"?

 

[o1marc]

Cut and replace/patch after using a rust converter and prime/paint the floor.

 

[brokedown-SKO]

Does it all look like that of is that just a pic of the worst spot? Rust converter can give you useful steel from areas that aren't too far gone, and you can patch areas that are beyond help. If you intend to replace your ceiling, that's a bunch of free donor metal even.

 

[Tango-SKO]

The floor is significantly heavier gauge steel than the roof. Probably at least 14ga. where the roof might be 18 or so. Always best to try and match whatever you are repairing so using a sheetmetal gauge is where I would begin.


Also check to see if the existing metal is galvanized. Some is, most isn't from what I have seen. You do NOT want to be welding galvanized without proper prep and/or gear. It can screw you up in just a few breaths. All the zinc needs to be ground back from the weld zone or wear a proper mask.



For anyone not familiar with this problem...




https://www.bakersgas.com/weldmyworld/2011/12/03/side-effects-welding-galvanized-steel/

 

[vintageracer]

Cover it back up and sell the bus.

Find and purchase a BETTER bus using you new newly acquired SKILL as a rust inspector and other skills learned from this first rusty disaster.

You, your pocket book and most importantly your valuable time will thank you for making this tough decision!