Entry/starwell wall

Got the stairwell wall and handrail thing built. I’ll cover with an upholstery panel soon. This frame was difficult, because of all the little connectors and features it needed.

Forgotten Rust

So if you recognize what movie scene this is, you’ll know how I felt tonight about my entry steps…

I am now working on the entry and the kneeboard/barrier/thing that keeps passengers up front from falling into the stairwell and also something to bolt the handrail onto.

Since I’ve had the bus I have left the original vinyl step covering on the treads. Well, time to fix that.

I thought I’d get back to the project roots and show some rust removal.

First step was to unscrew most of the screws holding the vinyl down, then grind the rest off. (Hey there’s that burning pine-sol smell when grinding, ah memories…)

Next was ripping up the vinyl up, then these terrible tin tread covers/rust traps.

Thus behold the rusty glory:

I don the full face respirator and hearing protectors, and needle scale the rust and old adhesive to this:

Follow up with a flap disc to remove more rust to this:

Then phosphoric rust converter attempt 1 and 2 get it better, but the pits are really deep still.

So, wire wheel, DA sander, and a belt sander again. An application of rust Mort later gets me this:

Clean up with some lacquer thinner, and let everything chill for the night. I’ll spray a decent 2k epoxy on the floor (no more galvanized metal there…)

After that, I’m undecided on the final look other than a big rubber floor mat for catching dirt. Maybe some grip strips on the tread…


Plywood panels on steel frame

Sticking some plywood where it needs to go. To be covered by birch ply, plastic, aluminum, or other.

Metal framing makes all of this so easy. Self drilling lath screws are perfect. The gap between is filled with wires, plumbing, nothing, or sound deadening material.

Panels and ply experiments

Goofing around with the panel stuff. I’m finding steel framing affords a lot of flexibility for interesting ways to connect stuff.

Precision cutting plywood sucks. I hate working with wood.

Got the last interior surfaces on the bed area. This was a pain in the butt too, because of tight clearances and the need to ensure that everything is laid down flat. This will become a set of shelves for the kids stuff, I have place 9″ deep x 74″ wide by about 30″ tall for each of the 4 bunks. Some sort of shelf with bungie netting to hold things in probably.

Last bit of ceiling and more framework.

Getting that last bit of something done always seems to take the longest. I am pretty sure I just finished all the major structure for the interior – the steel tubing and such. To celebrate I re-hung the interior overhead panel in front too.

I am undecided on cutting a big hole in the middle of that front panel for storage, leaving it alone, or something else. Like everything else, it needs a trim panel because the ceiling is higher than before.

This bus is a series of tubes.

Nice to beige you again, beige.

Cabinet birch ply

Picked up some finish grade birch, some structural lower grade ply for storage shelves and carpet to line some things.

I also picked up a pane of polycarbonate greenhouse panel, I will use some as trim somewhere I think, for translucent panel location.

Dog is my co-pilot.

Some more kitchen cabinet frames and general fabrication

Not shown: horizontal stuff that makes that upper cabinet a little more rigid. But! This is a great example that I think demonstrates the versatility of steel tube.

All this stuff gets covered with luan or plastic or something else.

Here you can see I got tired of the PA hole. I could not seem to find a new horn the right size.

At some point I’m going to have to paint this beast for real. I was thinking of Sherwin williams shurthane 2k. Any thoughts? It’ll be about 3 weeks of sanding prep I bet. Ugh.

At least i can plastic off the outdoors while I work on the finish.

Whats it look like now?

I kind of forgot what it looked like, so I backed out of the covered area. Now I can work in the shade doing fab work instead of frying in the sun. I don’t know why I didn’t do that the last couple weekends.