Categories
Stage 4 Interior

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 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 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 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

Categories
Stage 2 roof raise

Week 8 of 2023

Light at the end of the tunnel

Another week of skinning, but the end is in sight! We skinned over the to-be-shower window and nicely enclosed that.

We re-installed the engine air inlet and discovered how steel paint is very unforgiving; every scratch and blemish under the paint can be seen. So we will have to do a LOT of work to get the bus paint-ready later.

Family work day

Saturday was another family work day. M worked on the wiring. The wiring to the external side and roof lights was cut for the raise. They will need to be reconnect to be road compliant, so M went around and reattached/lengthened the wires. Meanwhile, R and N cleaned the side supports so they are ready to be painted and put back.

While they were busy with that, we put the window skins at the back end of the bus in place, as well as the big horizontal piece of skin that now makes it look like the bus is wearing a hat.

Can’t even see that we had to cut off 2” length wise to make it fit. That two-inch strip we later used to cover some unused screw holes where the disability door used to be. Last but not least we mounted the corner steel, which even though amateuristic, look pretty fancy in our opinion. All in all we have covered up three of the windows by now and we think we will leave it at that.

We have now reached the point that we only have the roof transition piece left. With three weeks left in our current storage unit, we are hoping to get that completed so we can downscale to a smaller, cheaper unit. Saving $100 a month would be welcomed!

Categories
Stage 2 roof raise

Week 7 of 2023

Skinning Continued

This week we continued skinning the bus. Since it is a two person job, we can only do this when we are both available at the same time. Saturday afternoon after archery and Sunday afternoon after church it is!.

First sheet going on the back of the driver’s side

Definitely a marriage builder….

As of now, we have the sheets on both sides of the bus in place. It makes it look so much better on both the inside and the outside!

Need more steel

It looks like we are slightly short of plate so we will have to get another sheet. We skinned a few of the window openings as well; one on each side of the future bedroom and one where the shower is going to be. That will leave space to install a fan so we keep the humidity out of the bus when we clean ourselves up.

We finished the door frame of the little door. Whenever we have a small sheet available we will put the extended door in place.

We welded two more bars inside of the bus to attach the top of the sheets that are covering the disability door. It all looks nicely closed up now

Categories
Stage 2 roof raise

Week 6 of 2023

First sheets!

This week we managed to get the first few sheets of steel on the side of the bus. We figured out that all those strengthened supports now won’t take any of the said-to-be self-tapping screws from China due to the thickness of the added steel. If it’s not too thin, it’s too thick. Looks like we will be returning the screws to China.

Raise the first panel

Family work day

The girls came out on Saturday and started to clean the bus window frames so we can put everything back nice and clean after we are done with the siding. Even N helped sweep up to keep the storage area clean. Meanwhile, R dismantled some of the strengtheners from the wheelchair door that we will put back on the bus.

Getting the sheets in place is a two-person job. Blinding off the (former) wheelchair opening gave us quite some trouble. Lining up the steel without leaving gaps was not an easy task. On top of that, the adhesive sealant made a big mess on the steel as well as on us.

Luckily, we won’t be able to see it when it is all painted on the outside and covered up on the inside. The first corner transition was added at the door as well. It seems that the bending brake we bought is not suitable to bend 18 gauge steel, so we went one size smaller. This won’t affect anything since the corner sheets are merely covering the gaps and don’t really have a structural purpose. Slowly but surely, we are putting the bus back together.

Installed corner sheet
Categories
Stage 2 roof raise

Week 4 of 2023

Slow and Steady

This week we finished the air inlet and the remaining insets at the back of the bus.

A few of the items completed this week:

  • welded a frame for the wheelchair door that will be covered up.
  • cleaned up the glue from the inside back of the bus and welding a support frame to put behind the AC unit.
  • welded the back corner supports to make sure we can fold the sheet metal around it and added brackets on the inside to make sure everything is solid and cannot move.

A/C Unit struggles

We now could lift the AC unit back into place, if it wasn’t for a small snag: The hoses that lead to the evaporator are now about two feet short. And we are not sure how to either cap or drain the freon while putting a hose extension in between. If there is anyone on here who knows how to do this – the assistance would be greatly appreciated.

Short hoses need to be replaced to raise the A/C Unit

Main door problems

Meanwhile, we also re-straightened the main bus door. Apparently, the doors were out of line to start with when we got the bus.  Once we got the doors aligned top and bottom with seals closed, the locks on the doors no longer aligned. We will have to shift one up 1/4″ to be able to place the lock through it. It’s merely a small inconvenience that we can fix at later date.

Next on the job list is to fix the door frame and door on the driver side of the bus. We have to make the door and its frame two feet longer than it is now. After that we can work on welding the transition frame on the front part of the bus. Still a few days to go before we can start with the re-skinning,