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!