Thomas Minotour Build

[nikitis]

The wheel base on that 8 window is shorter than the van lol. That's just sad.

I've been eyeing one of those as well but a newer one with the rounded flat front nose.

This will probably be my next bus, and will be used for house living, not traveling.

15 Window. Do a 18'' roof raise.

I already have this 8 window dog nose and it's nice but tight for living, perfect for traveling.

 

[AlphaHare]

How many busses do you have? I think (I know) I'd have a domestic situation if I even contemplated another bus... ;>)

 

[nikitis]

I just have the one currently in my pic, but I'm thinking about buying a second 40 footer for living quarters.

 

[FawnaFox]

The wheel base on that 8 window is shorter than the van lol. That's just sad.

I've been eyeing one of those as well but a newer one with the rounded flat front nose.

This will probably be my next bus, and will be used for house living, not traveling.

15 Window. Do a 18'' roof raise.
View attachment 2409981

I already have this 8 window dog nose and it's nice but tight for living, perfect for traveling.

Too small for living? I'm going full time with 2 roommates in my bus...

 

[AlphaHare]

I'm done spending time under the bus (on this side anyway). All three body mounts installed, and got the stairs in permanently. They will get additional welding to the inside of the door jamb once that gets fitted. They feel really solid underfoot.

I had to do a little bit of fitting going back in - there was some movement from the welding - but it was tight to begin with. NBD.

It is soooo nice to have this done. And to walk in and out. ;>)

 

[AlphaHare]

There are some tight spaces under a bus between the frames and rails and muffler.

I've had this right angle attachment for an embarrassingly long time (unused).

I had to drill one 1/2" clearance hole - totally worth it - there was no other way.

 

[Bjorkinman]

There are some tight spaces under a bus between the frames and rails and muffler.

I've had this right angle attachment for an embarrassingly long time (unused).

I had to drill one 1/2" clearance hole - totally worth it - there was no other way.

That's a solid looking right angle bit. NOT from harbor freight I'd imagine.
The pic makes it look like a magazine ad with the lighting and what not lol.

 

[AlphaHare]

Thomas did some remarkably crude cutting to put in the original stair well. The welded bracket is theirs too. I cleaned it out, undercoated everything, and I'm just going to cover it up.

Last pic is the passenger skin going on, and the start of door skins. Pretty excited to get the door swap DONE.

 

[AlphaHare]

That's a solid looking right angle bit. NOT from harbor freight I'd imagine.
The pic makes it look like a magazine ad with the lighting and what not lol.

I think it's a Milwaukee. I was surprised with how well it actually worked. Hex fitted end so plenty of torque with no chuck.

 

[Mr. Beefy]

Beautiful work!

Is that your toilet in the background? Can't take 5 minutes to go inside like a decent human being?

Also, did you replace all your body bushings? Maybe I missed that if you've documented it already.

 

[AlphaHare]

Thank you!!

The toilet is from the barn owners old RV and happens to be about the same shape as the one I'm considering. Just there for space mock up.

I only rebuilt the bushings supporting three of the C channels (and I still have to do the other side.) The original mounts were intruding on space I wanted for tankage. I've left all the other bushings in place. They look 'meh', but still there and not madly oxidized.

 

[AlphaHare]

Door skins prepped and positioned today. Fussy work.

The upper part of the door is proud of the skin by about 0.75" - the result of the door being straight, and Thomas having a slight draft on the upper body. The stack-up of materials looks heinous but I can bend it down by hand on a ladder so I'm not worried. It'll all tack down nicely with the rivets.

Tomorrow is mostly about drilling about 250 highly visible holes....

Thomas has zero uniformity on these two body hoops - the spacing is sometimes 2.5", but many times not, or it changes spacing along the way. I've identified a few 'good' holes and then dividing the spaces between to about 2.5" with what my drafting teacher called "a series of approximations" with a pair of dividers.

I'm re-drilling everything from the skin side so it'll look nice. It is the front door - everyone will see it up close and personal.

And then some riveting!

 

[chumcity]

wow I wish I was that good with metal...

 

[AlphaHare]

@chumcity - Appreciate the comment, thanks! You've got great woodworking chops, CNC and CAD skills. No reason you can't do the same in a different material. ;>)

 

[chumcity]

Thanks!
Building around twisted, out of square busses will your skills sharp alot quicker I think

 

[AlphaHare]

Door side skins done, door hung. Need to do some fitting for the lock, and the windows should be here in a week….

 

[AlphaHare]

Fitted foam for the leading and trailing caps. Just like making a surfboard - a lot of sanding and fairing work to do. Fiberglass this weekend as it warms up a bit…

 

[Bjorkinman]

Door side skins done, door hung. Need to do some fitting for the lock, and the windows should be here in a week….

Nice man, you gonna put a window?
Get lots of pics of the fiberglass, id like to see how thats done, should look good when its all done.

 

[AlphaHare]

There is a 15"x29" window for the door, and a large window in the passenger wall with a smaller one in the foot well. Most of my windows are here, and the last few coming shortly.

I've done a lot of fiberglass work in various forms over the years. It may seem intimidating, but if you can do paper mache then you can do fiberglass. Wear more PPE... Any clothes will instantly become workshop-only clothes with the addition of epoxy resin. The only magic with the XPS foam is to use epoxy resin. Polyester resin (and hardener) will eat it up.

 

[AlphaHare]

Foamed the front nose for a tight fit today. With the door closed a small radiator warms the bus right up! ;>). I have black poly trash bags on the roof to keep it from sticking.