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Big Yellow Project
Well here's the saga of the latest bus repair. It seems a new driver at a local high school was attempting to back out of a parking space and missed the BIG YELLOW vehicle already occupying where he intended to move. Maybe they should change the color of those buses so you can see them coming.
http://i5.photobucket.com/albums/y16...s/IMG_2023.jpg Note door gap closed up here... http://i5.photobucket.com/albums/y16...s/IMG_1911.jpg http://i5.photobucket.com/albums/y16...s/IMG_1909.jpg http://i5.photobucket.com/albums/y16...s/IMG_1907.jpg http://i5.photobucket.com/albums/y16...s/IMG_1905.jpg http://i5.photobucket.com/albums/y16...s/IMG_1904.jpg http://i5.photobucket.com/albums/y16...s/IMG_1903.jpg http://i5.photobucket.com/albums/y16...s/IMG_1900.jpg So from the onset, it looks like we need one new door, a filler panel, some "adjustments" to a couple door frames, painting and buffing. Filler panel was fabricated out of 18 ga cold rolled steel, abraded with the DA, and prepped for SPI epoxy primer.. http://i5.photobucket.com/albums/y16...s/IMG_2025.jpg New door and filler panel have been sprayed with SPI epoxy, here shown after blocking with 400 grit.. http://i5.photobucket.com/albums/y16...s/IMG_2044.jpg New hardware getting prepped for painting... http://i5.photobucket.com/albums/y16...s/IMG_2045.jpg Stainless hardware is used to stave off the rust issues. The bright polished finish does not provide good adhesion for a paint finish. Additionally, we've found that excessive paint build on these promotes cracking/chipping of the paint while driving them in during installation.. So to minimize the build on the hardware, we have eliminated primer on these parts. We media blast with 80 grit garnet media, blow off with air, and they get yellow urethane directly on the abraded fasteners. This method has shown to work well with NO chipping... http://i5.photobucket.com/albums/y16...s/IMG_2046.jpg http://i5.photobucket.com/albums/y16...s/IMG_2047.jpg http://i5.photobucket.com/albums/y16...s/IMG_2053.jpg http://i5.photobucket.com/albums/y16...s/IMG_2052.jpg Dis-assembly.. http://i5.photobucket.com/albums/y16...s/IMG_2060.jpg http://i5.photobucket.com/albums/y16...s/IMG_2063.jpg http://i5.photobucket.com/albums/y16...s/IMG_2064.jpg The filler panel is actually sandwiched between two flanges at each luggage box, so the bus needed to be jacked up about 8" where the filler panel could be slid in place from the bottom, and bus dropped back down to level before attachment so we didn't have any twist in the boxes. http://i5.photobucket.com/albums/y16...s/IMG_2065.jpg http://i5.photobucket.com/albums/y16...s/IMG_2067.jpg http://i5.photobucket.com/albums/y16...s/IMG_2070.jpg All door gaps addressed, painting, touch-ups, and buffing complete, ready for school! |
Re: Big Yellow Project
It looks much better ,shame they cant be a brighter color so they can be seen better .
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Re: Big Yellow Project
Always a new challenge every day....
http://i5.photobucket.com/albums/y16...0/IMG_2379.jpg http://i5.photobucket.com/albums/y16...0/IMG_2382.jpg http://i5.photobucket.com/albums/y16...0/IMG_2383.jpg The strong winds this weekend knocked over a dead oak tree across the chain link fence at the local high school, and this was the bus that found the overhang.. |
Re: Big Yellow Project
:) job security one might say
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Re: Big Yellow Project
Nice job on the repair BTW
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Re: Big Yellow Project
He's got just shy of 20 buses, so odds are that I have at least one repair a year. This is the second in a 3 month span. :lol:
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Re: Big Yellow Project
Tonight found us working on the bus to remove some of the damage from an oak tree. Here's our damage...
http://i5.photobucket.com/albums/y16...0/IMG_2553.jpg http://i5.photobucket.com/albums/y16...0/IMG_2555.jpg The headliner above the step area was cut out to give us better access to the roof skin.. http://i5.photobucket.com/albums/y16...0/IMG_2594.jpg http://i5.photobucket.com/albums/y16...0/IMG_2595.jpg http://i5.photobucket.com/albums/y16...0/IMG_2596.jpg We got much of the damage roughed out, but there's quite a bit of stretch in that roof skin still to remove. http://i5.photobucket.com/albums/y16...0/IMG_2599.jpg http://i5.photobucket.com/albums/y16...0/IMG_2600.jpg |
Re: Big Yellow Project
With all that practice, I can only imagine what your truck looks like!
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Re: Big Yellow Project
A few more hours was spent getting the light opening to match the new, unbroken light, we welded up some of the screw holes that had torn, and given some of the structural members in the way of the roof, we had to settle for no oil canning and a slight low that needed filler.. The owner was more concerned about leaks than having the roof top that no one can see returned to perfect. Here's some of our implements of correction
http://i5.photobucket.com/albums/y16...0/IMG_2605.jpg http://i5.photobucket.com/albums/y16...0/IMG_2607.jpg http://i5.photobucket.com/albums/y16...0/IMG_2608.jpg Last night we finished up sanding the roof repair on the bus, and started to get things covered up for primer.. Being the lighter of us two, guess who got roof duties for rolling out the shark grip? http://i5.photobucket.com/albums/y16...0/IMG_2644.jpg This is starting to look like a hazmat incident... http://i5.photobucket.com/albums/y16...0/IMG_2645.jpg http://i5.photobucket.com/albums/y16...0/IMG_2648.jpg Tonight we'll get some SPI epoxy on the bare spots and filler http://i5.photobucket.com/albums/y16...0/IMG_2647.jpg The sheet metal on the front cap seems a bit thin for it's purpose, so rather than trust the new light to clip nuts again, a surround ring is made from 14 gauge cold rolled steel to make an anchor plate. The Vise-jigsaw is used to cut out the center... http://i5.photobucket.com/albums/y16...0/IMG_2649.jpg http://i5.photobucket.com/albums/y16...0/IMG_2650.jpg http://i5.photobucket.com/albums/y16...0/IMG_2651.jpg note throttle control... http://i5.photobucket.com/albums/y16...0/IMG_2652.jpg Using transfer punches, mounting holes from light are marked onto the ring and drilled to 17/64 to accommodate 8-32 rivet nuts... http://i5.photobucket.com/albums/y16...0/IMG_2654.jpg http://i5.photobucket.com/albums/y16...0/IMG_2655.jpg http://i5.photobucket.com/albums/y16...0/IMG_2656.jpg http://i5.photobucket.com/albums/y16...0/IMG_2657.jpg It was also media blasted to prep it for the epoxy primer session for this evening. |
Re: Big Yellow Project
All ready to spray...
http://i5.photobucket.com/albums/y16...0/IMG_2663.jpg Here's the SPI epoxy sprayed on the repair area... http://i5.photobucket.com/albums/y16...0/IMG_2664.jpg as well as on our bolting plate we fabricated. This will be riveted behind the panel using stainless pop rivets.. http://i5.photobucket.com/albums/y16...0/IMG_2665.jpg First coat of BASF Urethane, and a shot of the scaffolding setup used... http://i5.photobucket.com/albums/y16...0/IMG_2670.jpg Final coat... http://i5.photobucket.com/albums/y16...0/IMG_2676.jpg https://www.youtube.com/watch?v=AiYA19ELpj8 Unmasked, we'll let this set a bit and get it re-assembled on Tuesday night. http://i5.photobucket.com/albums/y16...0/IMG_2678.jpg |
Re: Big Yellow Project
Looking much better .
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Re: Big Yellow Project
Thanks!
All done with the school bus! To recap, Before: http://i5.photobucket.com/albums/y16...0/IMG_2380.jpg http://i5.photobucket.com/albums/y16...0/IMG_2555.jpg After: http://i5.photobucket.com/albums/y16...0/IMG_2680.jpg http://i5.photobucket.com/albums/y16...0/IMG_2682.jpg |
Re: Big Yellow Project
Looks good .
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Re: Big Yellow Project
Nice work; I appreciate you highlighting the steps.
I don't envy you, though: that's a lot of YELLOW. (Looks like you have a nice place to lay out your tools while working....) |
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