Categories
Stage 1 rebuild

October / November

Life is busy, but we are making slow progress. That said, our timetable has been adjusted once more. Slow and steady wins the race. What we have done in the past weeks:

October

We added a shelf and electrical cables to each of the girls’ cubbies. They will all have USB chargers, string lights, and a fan in the front of their cubbies and light and USB in the back of their cubbies. With the electrical work completed, we closed the cubbies off by putting the plywood on top, which will become our bed.

Plywood for bed

Installing the plywood for our bed into the bus required some navigation since the bathroom walls were already in place. We cut some holes and made little access hatches so we could still access the electrical wires later. Once all the plywood was in place, we had to figure out in which orientation we were going to sleep so we knew where to place our storage bins.

Next, we finished the trim around the windows. We had to special fit these so we can take the windows out when needed. Meanwhile, we painted the bathroom doors. We bought folding doors, removed the folding hinges, and will use them as regular doors instead to reduce the space required to open them. They don’t sell doors that size separately, so converting a folding door was a good solution.

Next, we built storage bins on the plywood bed for the parents’ clothes, creating quite a bit of storage space. We also added lights and USB chargers. Since there was not much we could do with that space, we covered the wheel wells and turned them into steps. We filled them with insulation to reduce the road noise.

Extra door

Then we moved to the side door. We kept this door in our bus to quickly access large items and ventilation when parked. It took a bit of thinking to re-design the door so it can be opened from the inside but not from the outside. Until now, we used a ratchet strap to keep this door closed. While working on the door, we discovered it did not close and seal properly, so we had to cut and reweld it again to make it fit better. Then, I added plywood over it, followed by the wall covering.

November

We added the flooring so we knew how much height to consider for the bathroom doors. We finished the bedroom and bathroom walls and added the bathroom light and fan switches. Then the trim and the doors (I hope they will not warp) hung. Finally, we added the handles, locks, hinges, and AC vent closures. That finally completed the bedroom. Now we must figure out how to get a king-size mattress into the bus with already built bathroom walls….

Bathroom

The bathroom is next on our list, starting with a shower pan. It took a while to determine whether we should go with a full stall or a shower curtain. We chose the latter to have more space when the shower is unused. This meant we had to cut a hole in the drain. Fortunately, in the beginning, when we put the subfloor in place, we had already marked the location of the frames under the bus, so we managed to put the drain where there was no framing underneath. But of course, there was an outside storage bin that we had to remove. Which was too large to get from underneath the bus, so we had to cut up our precious storage box.  Once the cut was made, the girls ensured the hole was big enough. Then, we glued the shower pan in place and added some weight on top until the glue dried.

Next, we installed the bathroom ceiling and light before adding the shower wall. We used Polysterene backer board for the shower. It is easy to cut and pretty light. We used Palisade tiles over the backer board. Next time we visit the bus, we will see how that holds.

The beginning of December is busy with family life as usual, but now that our dining room is full of materials after Black Friday, we will have to take some days off to finish the bathroom.

Categories
Stage 4 Interior

August/September

After the last update, we brought the bus back to storage. We can do several things without the bus in the driveway. Those are caulk, electricity, and paint. This is what we did in the last few weeks. We filled the screw holes in the ceiling, caulked, and painted that. Then we painted the plywood in the back and the trim. All in all, three coats each, so with the bus in storage and dry times accounted for, this took a few days.

Girl’s Beds

Once the painting was completed and we had a free weekend, we brought the bus back to the driveway to start the installation of the girl’s cubbies. The girl’s beds are at the back of the bus, side by side running front to back. We divided the space with plywood walls to create their own “cubbie”.

They picked out their own paint colors and spent the weekend painting their cubbies, making it their own space.

Meanwhile…

While they did that, we added a storage shelf in the back for future storage baskets. It is starting to look like a real livable space in there! Once the cubbies were painted, we added the top supports and ran the electric tubing so we could add wires while the bus was back in storage. A lot more caulk and a lot more trim are making it look more and more like home. The girls are very excited to start seeing the end product!

Working our way forward

With the cubbies and trim completed, we could add the wheel well covers. We filled those with insulation to cut down on the road noise. There is no real usable storage space in there, so we just closed them up. Eventually, they will be covered with flooring.

Walls and ducts

Then, it became time for the bedroom walls. We stained the tongue-and-groove wood to balance the paint colors. Last, we added the AC ducts. One side will go into the bedroom and bathroom, and the other will lead to the living room. We hesitated between painting the ducts or leaving them metal, but we are glad we painted them white allowing them to blend in with the ceiling better.

After a week, the bus went back to storage. While there, we will finish the electrical work in the bedroom, continue working on the back door, and finish the walls.

It is slow, but we are finally starting to see some progress! Next up – the bathroom….

Categories
Stage 4 Interior

June/July 2024

Water tank

We are excited to be officially building out the inside of the bus. This started with closing in the water pump area and building coves to hide the cables and hoses in the back of the bus. The cove sections were made removable to allow for easy access for when we need repairs or add wires.

Ceiling

Next, we screwed furring strips onto the metal roof and side channels. Research found comments made by owners of finished skoolies that they have issues with moisture leaking from the screwheads on humid days. Adding a furring strip ensures a buffer between the steel and the wood ceiling of the bus. We use steel screws to mount the furring strips, then use trim head wood screws in the ceiling panels that screw into those furring strips. Using trim head screws also means they are not as visible once the ceiling is installed. The furring strips also create nice coves that we can hide all the electrical wiring behind.

So much to do!!

It is quite hard not to jump from one side of the bus to the other in the build-out since completion is so close! We just want to finish it all at the same time! While it’s exciting to be nearing the end, it’s crucial to adhere to the plan to avoid getting sidetracked. Therefore, we keep working our way from the back to front.  

First – the bedroom

Build out begins at the back of the bus with the bedroom. We built storage compartments underneath the area where the girl’s cubbies are going to be. Then we added the horizontal supports where our bed is going to be. We had the girls sit in their areas and we adjusted our bed height from there. We want to make sure they can sit up in their cubbies, so it doesn’t feel like they are sleeping in coffins. This is where that roof raise becomes well worth the time and money. How will we get into our bed since it is about 4 feet off the floor? Well, that’s a problem for later….

But before we can finish the beds…

With the bedframes completed, the logical next step would seem to be finishing the cubbies, installing plywood for the bed, and then addressing the rest of the bus. However, it is much easier to install the ceiling panels before working on the cubbies. But in order to install those ceiling panels, we need to determine the placement of the bathroom walls. Consequently, we had to frame the bathroom next. To do so, we needed the sink so we can determine bathroom size. So we ordered that. This illustrates how quickly the focus can shift from one task to another.

Adjusting as we go

When working on the wall layout, the bathroom window appeared to be about 4” off our scheduled floor plan. So we had to be a bit inventive with the wall framing. We prefer not to cover any more windows, and we want to be able to take them out in case one breaks or starts leaking. As a result, the framing had to be adjusted to compensate.

While building the walls it also seemed our bedroom changing area would become a bit too small. In view of this, we moved the walls just a few inches more which will affect the kitchen and walkway. This became a problem for another day.  

Back to the ceiling

With the bathroom framing now in place, we could start on the bedroom ceiling. We went with a shiplap ceiling so we can (hopefully) remove a single ceiling panel to add some wiring in the future, painting the slats prior to installation. We incorporated the ceiling fan, speaker, and lights as we were installing the panels. With some of the leftover wood, we also finished out two of the overhead storage compartments.

Next we added the air vents onto the AC in the back, caulked the bedroom panels and ceiling, and added veneer to the visible ends of the plywood. M helped iron it on.

Not exactly in order…

Since the Depot had a sale on appliances, we decided to buy a fridge and microwave for the bus. We don’t have room to store the fridge at home, so we loaded it up after finishing work in the driveway. Now we need to decide where to exactly place it. With five of us, space is tight, so we have to make the most of our future kitchen counters and living area.

Next up is adding another coat of paint onto the ceiling as well as painting the wood walls at the back of the bus. Once the painting is finished, we can finish out the girl’s cubbies, frame out our bed and see what else we can do to add some more storage space. Finally, we will complete the bedroom area, focusing on comfort and coziness with soft bedding and personalized decor. Oh yeah and we have to figure out how to maneuver a king-sized mattress into this bus…

Categories
Stage 1 rebuild

It’s been a busy spring!

With three girls and both of us serving as leaders in multiple activities, spring is always a busy time in our house with camping, soccer, and awards. However, slowly but surely, we are making progress. Here’s what’s been going on:

February

It was time to start working on the inside of the bus now that the outside was complete. We can do a lot of things on our own, but one thing we cannot do is a/c work! We brought it to Saviors Repair in Pearland (www.saviorsrepair.com) to raise the evaporator unit at the back of the bus. Once raised, they would also install new hoses that are long enough to bridge the additional distance of the roof raise.

Shortly after we dropped it off, we got a call that there was no Freon inside the unit. It must have leaked out somewhere. Besides that, this will cost quite a bit of money since Freon is expensive. It also means we could have done the actual evaporator raise ourselves. But at Saviors, they not only supplied brand new hoses, but they also did trouble shooting for the leak. Within a week we had the bus back in our storage. We were very happy with the service!!

From there we spent a lot of time preparing for spray insulation. Taping everything off and putting plastic down to cover every square inch, because spray insulation does leave a mess. 

March

This month we installed the spray foam. We started at the back and worked our way to the front. Spraying the foam itself goes fairly quick. We just ran out too quickly resulting in time lost while waiting for the next order to come in. The worst part of using this type of insulation is the very messy shave down. Some spots expanded too much and had to be shaved flat to allow the walls to be installed. After all was cleaned up it looked pretty good!

April

In April, the brother came for another visit. We had two 100-gallon water tanks sitting in the dining room waiting for his arrival. Due to the type of water tank we could afford, we had to change the layout of the bus a little and place one tank burden. This will affect the location of the bunks for the girls. With the tank burden, there will be a bit of free surface movement during the drive when the tank is half full. We will have to wait and see how that works out, but I think because the bus is 32000lbs and the tank filled with water will be 834 pounds, it will not affect the driving conditions too much.

We opted for the convenience of PEX fittings for the installation, as they are simple “slip-on” couplings that streamline the process. After investing considerable time at Home Depot to determine our requirements, we had to make two additional trips for extra fittings. Our initial task involved cutting a hole in the side of the bus for the fill port and assemble the various components (such as pumps).

We then secured the water tank with a wooden 2″ x 4″ frame to ensure it would not move while we were driving. 

Water tank framed in

May

With the water tank in place, it was a matter of having a long weekend to start building out the inside. Some things can be done in storage, but building frames and cubbies just works easier with the bus in the driveway. As soon as we had the bus at home, we filled up the water tank and fixed the one hose we had forgotten to connect 😊 The remainder of the pressure test went without issues.

Starting at the back of the bus – the evaporator filter frame was re-painted and hung, more R24 insulation was added around the unit before closing it up with finished plywood, the bench was built up with plywood and the air conditioning control unit was encased.

This took a lot longer than anticipated! Due to travel, we had to return the bus to storage early. We will continue in June when we have our next weekend available.

Categories
Stage 3 Exterior details

January ’24

Finishing up the roof

This month we worked some more on the roof. Making sure that the goat cheese we are making out of our roof stays leak-free surely is a challenge!

We started out cutting a new cover for the emergency roof escape. To install that cover we had to clean off some more reflective tape and glue goop. One of the less fun jobs on the bus. We installed the cover with a lot of caulk and rivets, added the roof fan on top of it, then covered it with flex seal to hopefully make it water tight.

Having the fan in place does mean we cannot access the roof from the inside anymore and with the roof raised as it is, climbing on top has become a challenge of the roof

Adding supports

Next, with help from M&R, we installed several supports for the roof deck. We covered the holes with caulk from outside and inside to hopefully make it all water tight. The girls loved being on the roof to do this work! Of course we were short of brackets, so we had place another order and wait several days for that to come in.

Meanwhile, as we were working on the deck supports, I noticed the roof was starting to bend in one of the less supported areas where the solar panel legs are resting. Additional angle irons were welded on the inside to prevent further issues. Then we moved the bus back to storage for another week or so.

Prep work

Once the additional brackets came in, R & myself headed to storage to finish the additional verticals and to add the longitudinal deck supports. Then it was time to run over to McCoys for some redwood. Expensive, but since it is fairly hard, does not require much maintenance and simply looks very pretty, we chose to use this wood over pressure treated boards, which are heavier, or composite decking, which is slippery when wet.

Last weekend we took the skoolie back to the driveway to install the deck. It came out very nice if I may say so myself. Once completed we added a coat of weather shield to protect it. The wood will likely turn gray in the future, with very nice shades in it. Matches our color scheme perfectly.

Next up: Raising the AC. Now that will require a lot more thinking. We’ll see what next month brings.

Categories
Stage 3 Exterior details

2023 End of Year

No we have not given up!

Here we are at the end of another year! With school starting back up in August after our trip to Europe, all our extra curricula activities began as well, taking up weekends. Around all of that, we were busy getting everything ready to put the solar panels on top of our skoolie.

Solar Panels Frames

In all our research, we found so many stories about solar panels flying off the roof of skoolies. We are going to do our very best to make sure that doesn’t happen to us!

We verified how much spacing there would be between the brackets on the roof and the frame. The panels need to be as close to the roof top as possible. Not only to reduce the height of the bus, but also to be able to secure them better.

The frames for the panels will be touching the roof in the center of the bus but on the edges of the frames, we have a curve to deal with. We had custom legs with brackets manufactured to overcome this issue and welded them to the frames.

The brackets will simply angle with the bus roof as needed. Once those were in place, we welded the frames together. We have one frame in front of the ventilation hatch and three behind the hatch. That leaves some space for our future roof deck all the way in the back of the bus.

We painted the frames upon the completion of welding. Hopefully the coat is thick enough that they will not rust away! Next, rubber strips were glued down along each edge of the frame in hopes of reducing any noise made from vibrations.

Installing the frames

Once all the frames were ready to go, we finally brought the bus home. We removed all the old caulk from between the roof panel connections, replaced it with new caulk and then sprayed flex seal on all rivets and roof seams to ensure they will not leak. We cannot access most of them after the solar panels are on, so even though it is tedious, it must be done right.

Note to future skoolie builders: don’t use spray paint of flex seal on your roof after painting the side of your bus when it’s a bit windy; now we have to repaint some of the sides again…

Next we installed the solar combiner box, that we received from some nice friends 😊 This will combine all solar panel wires into one distribution box. This way, if one solar panel is covered by shade, the panels exposed to the sun will still have output, unlike if we would put them in series together.

Playing with big toys

To install the frames and panels, we had to bring in some large equipment. Fortunately, we have extended family who have access to such equipment. We could not have achieved the next step without it!! With a bus and a boom lift in the driveway, parking the cars was a challenge but we were so happy to work on this milestone!

The frames were rigged under the boom basket. R was on top of the bus to rotate them in position and land them on the bus. Then we did some final adjustments to make sure they were straight and not overhanging the side of the bus. Several hours later, the frames were in place.

Once all the frames were in place, we drilled holes in the roof of the bus, then bolted the brackets through the bus roof to nuts inside the bus. A two-person job for sure. 24 bolts and nuts and two days later, they were all mounted, caulked, flex sealed and tested. Quite some work! It’s always scary to drill so many holes in the school roof.

Next, we mounted the bus roof wire-receiver box and drilled 8 more holes through the bottom of the box and the roof of the bus to feed the panel wiring through.

Installing the actual solar panels

Then it was time for the solar panels. It took a little bit to figure out how to do the connectors but once we had that down, the install went fairly quick. We lifted a panel on the roof and placed it in the frame. While it was still connected, we both had to get onto the roof – one to lift the panel, the other to connect the wires to the panel. Once that was done, the panel was lowered and fit checked. We zip tied the wires along their path to the wire receiver box, pushed them through and cut them to size, put another connector on each end and repeat the steps for all four panels.

It was another solid day and a half of work, using a lot of caulk and flex seal in the process. Last step was to bolt the panels to the frames to ensure they don’t blow away. A long week, but in the end, we got it all done.

Inside the bus, we put connectors on all the wire ends and connected them to the solar combiner box. Then we had to wait for rain, just to make sure there are no roof leaks. And rain we got. Lots of it. And leaks too. Lots of them, but fortunately NONE of them in the roof. The side panels and windows of the bus were a different story though. But better to find them now then finding them after putting all the insulation in…

Next up…

 Next we will add another ceiling fan to make sure the future bedroom stays cool. Then add the roof deck and we can finally finish the insulation on the inside. After that, we can raise the air conditioning.

Still lots of work ahead. Stay tuned as we work hard to finish up by the end of 2024!

Categories
Stage 2 roof raise

Week 12 and beyond

It’s been awhile

Our last update left us having just finished the transition of the roof. Spring season was upon us with soccer, camping, awards, etc. Weekends were quickly filled up, not allowing much time to work on the bus. However, Ivo still managed to squeeze in an afternoon here, an evening there.

Sealing and protecting

With the transition in place, steel conservation was the next challenge. We had to make sure that with all those screws, all the holes and gaps are watertight. We used flex seal to achieve this. Flex seal is a rubbery coat that we spray on overall the areas that could potentially leak.

Next we had to get the little door extension completed done. We cut some sheet metal to size and welded it in place We added some corner strengtheners to ensure its sturdiness.

Cleaning again

Before applying any paint to the side of the bus, the roof had to be cleaned. It had gotten very dusty after all the cutting, grinding and welding. We first vacuumed the top and then wiped the entire bus down on the outside, top to bottom. Followed by placing masking tape where needed. All around the various activities of our girls (meaning this was a several week process)

In between all this, we went dumpster diving at our church since we noticed they had disposed of some mighty fine plywood and lumber that we took home and were able to obtain the wood necessary to build our beds.

We applied flex seal and primer on the inside of the bus, just in case the outside application proved not to be sufficient, then began painting the black section of the outside. Cleaning, sanding and painting took several more weeks.

More painting

We also repainted the rain gutters as well as the side support rails since they had faded. when we went to install the side rails, it appeared that due to roof raise they now were almost 6 inches too long. The unexpected things we run into…. So, we chopped a section off and welded the end back on to make it all look nice. Then we coated it with more black paint. After all the black paint was done, we added the white striping.

Then it was time for the maroon. In the pictures it looks quite red, but in real life it looks really sharp! The black took only two coats, the white took three coats and the maroon took four coats(!). We used paint brush and rollers since we are not experienced enough for paint sprayers. (plus we need to return the storage unit back in the same condition we found it in.)

Last but not least we started the grey. This paint just did not want to adhere properly. Even with all the hardener it simply would not go on. That said, the heat and humidity in Texas went through the roof by now so that may have been part of the problem. I just hope the paint won’t come off in sheets once we run a power washer on it in the future….

The little details

Next we put the little door back and added the new driver side window, those were two person jobs for sure, but it worked out! This was followed by a recleaning and re-installation of all the bus windows.

Finished up roof

 Then we needed to close the roof of the bus back up so we could change storage units. The one we painted in was becoming more and more expensive and out of our price range. We turned the forward emergency hatch into an electric fan location. This involved cutting new steel, removing the old hatch gasket, a lot of goo gone and more flex seal. Then we installed the fan.

At the same time, we removed the old roof vent and closed it up, so that in the future we can put a solar panel in that location. More flex seal followed by paint.

Then it was time to clean out the storage unit. We deposited another 260lbs of steel at the scrap dealer, which all in all should mean that the amount of steel we took out has now pretty much been replaced with the same quantity of steel we purchased new.

And then finally… we could drive out! Connected the batteries and she started up just like that!

The bus looks AWESOME!!! The yellow roof stripe in the picture will turn white once we install the solar panels. It was alot of work, but so worth raising the roof. It cost us exactly 6 months to complete this portion.

Next on the list after vacation:

– we need to find a way to raise the evaporator without loosing all the freon

-Install the rack for the solar panels we ordered

– put the roof deck brackets in place

– then spray insulate the bus and

THEN we can work on the inside completion!

Categories
Stage 2 roof raise

Week 11 of 2023

Milestone Week

We hit a milestone this week! The transition is complete! Finally all the skinning is done!!! It sure was not easy to get the transition in place. We first tried to make a paper mold. That blew everywhere and did not deliver good results. Then we tried to hoist a piece of plywood up there. That did not do any good either. Lastly, we cut one of the sheets at 65 inches, hoisted those 60 pounds of steel up onto the bus and marked it with a 1 ½ inch piece of steel at the bottom, following the curvature of the bus. We took the steel plate back down and used the electric scissors to cut that curvature and one side of the sheet to make sure it would lay straight along the center support. Then we hoisted the sheet back up there. Quite the exercise I must say. We used two ratchet straps to make the steel curve over the supports.

Making it fit

Following we screwed down the bottom of the sheet, letting the steel fold itself over the transition supports. Then we screwed in the side above the drivers window. In the end, there was so much curve in the steel that we had to make an angled cut to release the pressure and then continued screwing the plate down. We then made several vertical cuts on top of the bus and folded all the little steel flaps over the existing roof and screwed them down as well. Then we welded all those cuts back together in the hope to prevent future water leaks.

We repeated the process for the passenger side of the transition, which turned out a lot better. I guess we learn by doing. Murphy’s law dictated that we ran out of screws just before completion. Since we already emptied the Alvin and Pearland Depots of the steel screws we needed, a trip to the Bay Area Home Depot was necessary to deplete their stock as well.

Accidents happen

Having learned from our past rust-mistake, we wire wheeled the steel, vacuumed all the steel remains and dusted off the bus roof. While doing that, I lost my balance and proceeded to crash down with the ladder, shopvac and cleaner liquid bottle in hand. I really noticed that additional 20 inches of air space we created with the roof raise when that happened; it gave me that additional few hundreds of a second to realize that the landing after an 11 foot drop was really going to hurt….

So we had to fix the ladder, re-assemble the vacuum and re-clean the storage space since there now was dust everywhere. Then we could get back on task and wipe the rust remover on the steel followed by degreasing the steel using the now broken bottle of cleaning liquid and then we put on a first coat of primer. Quite satisfying I must say…

One more coat of primer and then we can slowly start to put the bus back together!

Categories
Stage 2 roof raise

Week 10 of 2023

Finishing up from last week

This week we finished the framing for the RV window. Of course, one of the verticals was just 3” too short, so we pieced two pieces together. In the end it turned out nice. Always a challenge to weld in the driver seat area since we set the steering wheel and blinker on fire before…

Driver Window

We also welded an insert above the door so we could mount the new steel against it. Then we added the drip rail and welded it all together. Little paint on it and it looks decent. On the driver side we did the same thing above the window.

Insert over driver window

Time is not our friend

Then we had a few days of not being able to go to the bus. When we came back, we noticed a very unpleasant surprise. We decided to wait until the entire bus was covered in sheet metal before painting. However, as everything tends to do with all the activities we are involved in, it has taken much longer than anticipated to get all the steel in place. Being on the gulf coast, bare steel is a bad thing. Though we are in an enclosed storage, it is not climate controlled. Bare steel + gulf coast humidity = RUST!

Especially where we had touched the steel with bare hands quite heavy oxidation had started. This resulted in a lot of additional work. We had to buy and apply a rust remover, then wire brush all the sections of steel, followed by more rust remover and then a degreaser. After that we applied two coats of primer. Would have been so much faster if we would have cleaned and primed right after installation….

Driver’s side

We hope we got it all the rust removed and cleaned properly so the paint won’t be peeling off in a year. Now all that is done, we can go back to our transition piece. Keeping a timeline seems to be very hard during this project. I am starting to wonder if the skoolie converters that claim they converted in a month actually did the work themselves….

Categories
Stage 1 rebuild

Week 9 of 2023

Small updates

We had a slow week this week. We are trying to get the transition covered, but to do that, we had to put the driver window back. During our trip from California there was a lot of draft coming from that window and it kept sliding open. It started leaking as we drove through rain in Houston. After some discussion, we agreed that it was best to replace this window with an RV window. They are much more solid and leak free then bus windows. Hence, we ordered one and had to wait for it to come in before we could continue.

We did start putting a transition piece in on the door side of the bus. We still have to finish it but did not get to it this week.

Once the RV window came in, we closed the opening with a full sheet of metal.

Once the metal was in place, we cut the hole out of it for the window. The top and bottom supports were welded into place. After setting our steering wheel and blinker on fire, extreme caution and concern was used welding in this area but we had no choice.

Once we had the hole cut we noticed since we overlapped two sheets at the top of the window, that things just did not fit right. So we ended up removing the screws, cutting the sheets and welding them together.

New driver window

It’s starting to look good, but we are not finished yet! More to follow next week