Last weekend and last of the windows

Matt and I had a plan of action for this weekend.  Getting the windows taken care of and being able to move onto the floors. Matt was able to get a lot of the windows disassembled while I worked on my car. We had removed all the windows on Friday night after work so he was able to just start in on the work.

Unfortunately I was detoured early on, my regular everyday vehicle wasn’t turning over.  Pretty sure the issue started after some really epic flooding happened the day before (flooding up to the curbs, had to take the super secret backdoor route out of work to avoid turning my car into a boat).  We ended up taking my battery to get tested, which cleared.  So I ended up buying a new starter and put that in which got my engine to turn over. Anyways, after that I was able to hop right in and start getting the panels off.

Took out the old top and bottom weather stripping, unscrewed the final screws located underneath the bottom weather stripping and got the panels off.  From there, pulled out all of the old fiberglass insulation.  This time I was a little smarter and had some trash bags around so I could throw it away immediately. 85+ weather and humid, long sleeve shirt, pants, safety glasses, bandanna, filtration mask, and work gloves.  Begin angle grinding! Unfortunately I didn’t get any pictures.  I only have so many hands, and Matt was thoroughly engrossed in taking care of the windows. Ran out of light by the time I was ready to paint.

Got all of the panels up and painted.  I got 3 of the windows up before I ran out of screens for the windows.  So we had to hold off until Sunday to finish up the rest of the work.

Well, we went out shopping on Sunday but got rained out when we wanted to work.  We went out and put up the last couple windows and marked where we had some water coming in. Plus side is that we managed to get done in a 10 hour day what took us about 3 and a half days the previous week.

Next up: 1. straighten out the dent in the roof 2. weld on the nozzle for the radiator 3. demo the floor 4. fill the holes in the floor

Some more shots from our first day

These are some other shots from our first day of work.  Tearing seats out, taking the ceiling off and taking out the insulation.  Also some engine shots as well as the old rusted out radiator surge tank (also, I had a heck of a time trying to figure out the name for that little metal tank).

You can really see the awesome non-working fix that was previously tried on the radiator surge tank. The new one was surprisingly cheap from We also bought the window latch/window thumb release from them.  It has definitely been interesting finding vendors for parts and figuring out what we need to buy and where to buy it from.

Parts and parts

These pictures are from a couple of weeks ago.  We discovered that the oil pressure sensor was broken (we originally thought it might be oil temp).  I showed the new one in some previous pictures but I wanted to show off the old one as well.  It took a little figuring to get it sorted out, but we managed to figure out what it was.

I’m also going to need to clean up the rubber off of the electrical connection heading to the interior of the bus.


The bus has a dent (it looks like a large tree branch or possibly a tree fell on it?) on the passenger side about the middle of the bus.  We’re planning to straighten it back out using a hydraulic bottle jack with a 2×4 on the end of it.  Some shaping hammers should help with it as well.

There are some minor leaks happening in the area around some of the rivets, so we’re hoping to get all of that straightened out as well.  Here are some pics of the dent:

Short hiatus

Decided to take a short hiatus while we were getting a ridiculous amount of rain.  Almost couldn’t leave work because the streets were flooded so badly.  You would think Tampa road commission or city planners would prepare to drain the streets considering there is a serious rainy season here?

Day 5

Installed the Emergency window before work and got a picture in.  Was talking with Verizon about why my dvr wouldn’t activate and decided to get some work in while waiting.

Matt is installing the emergency window in the last picture.  The screw holes weren’t lined up in the right spot.  We decided to shuffle the windows around which made re-installation a real pain in the ass in some spots.

Day 4

Got out of work early on Monday and just busted ass to get all of the windows up and finished.  Matt had read in a post on about someone putting up some screening over their windows.  One user had actually hand built screens with the frames and then he saw someone just install it with their windows and stretch it over.  So that’s what we went with.  Minimal effort with the results we want!

Ran out of sunlight, worked through the dark until about 1 am.  Long day, but got the emergency window painted but not installed.  Alas.. tomorrow.

Removing Windows

I think this was the 2nd day.  We got the windows out and figured out how to replace the window thumb locks.  Basically you take the springs out.  We’re going to do a video to show basic break down of a window and the painting process.  I cleaned up all of the rust behind the old insulation.  Looks like the little bit of rust was caused by open windows.

Took out the windows and the panels to get behind.  Had to rip out the old weather stripping on the bottom of the windows.  The screws for the panel were underneath it.  Most of it was in good shape, only a couple of the screws/areas had rust damage.  Overall still impressed with the lack of rust on the bus.  Long day of angle grinding for the first time and cleaning up the metal and getting windows ready for painting.

First day of real work

Posting this late.  Matt and I started on the bus.  The first day of real work was spent removing the seats and the ceiling shell.


We also needed to replace the oil pressure sensor.  Took the part into the local Navistar/International dealer.

Matt sanded down the old insulation and we managed to remove the rest of the chairs with the help of our roommate Jake. He hopped under the bus and saw that we had a nut on the end of the bolts, so we hunkered down and just had someone on the bottom holding the nuts in place.