Very nice work on that!
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Very nice work on that!
Thanks Ryan!
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.
Nice work, It looks like the lighter one of you two did not appreciate her photo being taken :LOL:
Haha! Winding down on the bus work so we can get back to some 55 seats..
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
More great work. I like the scaffolding too.
The bus is old so the paint has faded quite a bit. we've had 5 year old buses that matched fairly well but this one is over 7 years old IIRC. maybe the bright finish will deflect away the trees...
Only the school basketball players will notice.
Good One Charlie!
Looks good, I think that one would be pretty tough to blend.
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
Now we can go back to our regularly scheduled program!
Excellent work
Nice work! I have a curse of looking in the background of pics, I noticed that you have a 5 gal bucket that you tip over for the " I think I have one of those in here " moments. I believe I have 3 of those buckets under my bench :LOL::LOL:
That was the bus owner's stash. haha
With the 55's rear seat bottom narrowed to fit the wheel tubs.....
http://i5.photobucket.com/albums/y16...5/IMG_2641.jpg
....time to do the same for the seat back. First to blow it apart....
http://i5.photobucket.com/albums/y16...5/IMG_2713.jpg
This had a multiple fold down, arm rest in the middle, non 55 looking arrangement. The arm rest will be first to go, and we'll attach the fold down sections together..
The frame is sectioned in the middle, a tube driven inside, and TIG welded around the perimeter..
http://i5.photobucket.com/albums/y16...5/IMG_2714.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2715.jpg
Then the seat innards are trimmed accordingly to make a one piece back..
http://i5.photobucket.com/albums/y16...5/IMG_2716.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2718.jpg
Then some 14 gauge strips are cut out to join the two sections together..
http://i5.photobucket.com/albums/y16...5/IMG_2719.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2720.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2721.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2724.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2725.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2727.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2726.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2728.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2730.jpg
That should work, tomorrow we'll work on the new pivot brackets..
In removing the section of foam on the seat back we find the cushion has a wire around the arm rest void. As we are removing the arm rest altogether (when it gets reupholstered) we removed the wire..
http://i5.photobucket.com/albums/y16...5/IMG_2732.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2733.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2734.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2736.jpg
The previous pivot for the seats had a tapered pin hex bolt that secured into a hex nut that was welded onto the pivot bracket, which can be seen here:
http://i5.photobucket.com/albums/y16...5/IMG_2717.jpg
Due to our width constraints, we need to remove all that excess hardware.. So we chose to put the "securing nut" inside the seat, and use a simple pan head allen screw through the 12 gauge bracket.. Here's our Pivot "axle" inside the seat back..
http://i5.photobucket.com/albums/y16...5/IMG_2742.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2743.jpg
Here's the test fit of our 12 gauge steel pivot bracket. Radius was used on the bends to match the tube. The tube was originally round, and the side uprights were flattened out using the MH19 hammer to buy us some more clearance between wheel tubs..
http://i5.photobucket.com/albums/y16...5/IMG_2744.jpg
The bead shown on the bracket was done on the Lennox Nibbler.
This should give us a bit of clearance on the edges to help prevent binding of the upholstery.
http://i5.photobucket.com/albums/y16...5/IMG_2748.jpg
Bead turned out pretty well for 12 gauge steel! Some TIG welding to put the parts together:
http://i5.photobucket.com/albums/y16...5/IMG_2749.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2750.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2752.jpg
Video of it in operation:
https://www.youtube.com/watch?v=KCcpqbF1jUU
One part down, next we'll tackle the brackets to the floor.
Nice work, as always, Robert! Just curious if you considered leaving the seat back "split" so you could carry a long item while still having a backseat passenger? Although, I'm guessing this car won't be used for many trips to Home Depot!:LOL::LOL:
Thanks Randy, we're going to make the seat back fold down in one piece. Plans are for a void behind the seat for sub and amp. So it will be closed to the back side, and the fold down seat will permit the access to the amp.
Back in the shop this evening, time to make some bolting brackets to hold the seat back frame to the floor..
http://i5.photobucket.com/albums/y16...5/IMG_2799.jpg
Locating...
http://i5.photobucket.com/albums/y16...5/IMG_2802.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2804.jpg
Brackets TIG welded on....
http://i5.photobucket.com/albums/y16...5/IMG_2808.jpg
This shows it in place, we have about 1/4" clearance at the tight spots....
https://www.youtube.com/watch?v=jB5qRfP7IxY
The cleco's were removed and 1/4-20 AVK rivet nuts installed in the floor... Missed that picture...
http://i5.photobucket.com/albums/y16...5/IMG_2817.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2818.jpg
Next will be the top support....
More great work! Those brackets are very nice. I don't think I can do that with my vice. :LOL:
The vise was used in making them...
Now for the top of the seat frame... We started with some 3/8-16 standoffs that are 5/8 diameter, and turn them to 1/2 diameter to fit inside the seat frame tube...
http://i5.photobucket.com/albums/y16...5/IMG_2826.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2827.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2828.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2830.jpg
Then holes are drilled in some 1.25 square tubing...
http://i5.photobucket.com/albums/y16...5/IMG_2832.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2833.jpg
Tacked in place and a nut used for added insurance...
http://i5.photobucket.com/albums/y16...5/IMG_2837.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2836.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2839.jpg
Seat latches plug welded in place...
http://i5.photobucket.com/albums/y16...5/IMG_2844.jpg
Side pieces formed....
http://i5.photobucket.com/albums/y16...5/IMG_2842.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2856.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2847.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2848.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2849.jpg
The side pieces will be trimmed, fitted, and welded to the wheel well...
http://i5.photobucket.com/albums/y16...5/IMG_2855.jpg
Very nice pics showing how to cut those tubes to get the rounded corners! Thanks for that. I'll have to remember that one.
Couldn't have said it any better.. thanks R2
Seth, :LOL:.
After making the relief cuts, tap the corners around first, then worry about the flats in the center of the tube. If you hit the center first, you may wind up with a low area in the center.
Thanks for the comments guys!
It's amazing how the smallest "Tip" can make a big difference.;) Thanks Robert for the visual and verbal tips.:)
Jack.
More work on the seat back bracket... Trimming the side pieces to match the wheel well...
http://i5.photobucket.com/albums/y16...5/IMG_2860.jpg
Adding welding flange, hammered out of 16 gauge steel..
http://i5.photobucket.com/albums/y16...5/IMG_2864.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2866.jpg
Test drive....
https://www.youtube.com/watch?v=mpFl01yHvKw
Used the Roper Whitney hand punch to make our plug weld holes..
http://i5.photobucket.com/albums/y16...5/IMG_2871.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2872.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2873.jpg
http://i5.photobucket.com/albums/y16...5/IMG_2875.jpg
Next we'll close off the back area to contain the amp and bass speaker.
Had a short evening in the shop as I was busy packing the neon clock for shipment, so the remainder was spent working on some of the many final details of the rear seat. Here are the factory seat clips to hold the seat bottom in place.
http://i5.photobucket.com/albums/y16...5/IMG_3149.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3150.jpg
In order to use these, let's do a sample and see if we cut a hole in some sheet metal that they'll fit into..
http://i5.photobucket.com/albums/y16...5/IMG_3145.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3146.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3147.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3148.jpg
This looks like it will work, we'll get some 18 gauge strips made to hold these that 45 down to the floor, adding some bead details for strength..
http://i5.photobucket.com/albums/y16...5/IMG_3151.jpg
Time for some brackets for the rear seat bottom retainers. Cut out some 19 gauge...
http://i5.photobucket.com/albums/y16...5/IMG_3152.jpg
Drilled some holes for an inside radius, and trimmed the corners for the floor pan flange..
http://i5.photobucket.com/albums/y16...5/IMG_3154.jpg
Now to fold some flanges on the sides for strength, using the Diacro press brake and a 1/2" thick lower die. By adding some rare earth magnets to the back side to serve as a back stop, we get a perfect 1/4" flange...
http://i5.photobucket.com/albums/y16...5/IMG_3155.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3156.jpg
Then some back and forth between the Erco kick shrinker and the press brake with a narrow die inside the folds.... and we have 45* bends on either end of our brackets...
http://i5.photobucket.com/albums/y16...5/IMG_3157.jpg
Test fit.... and trimming the retainer hole...
http://i5.photobucket.com/albums/y16...5/IMG_3160.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3161.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3162.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3163.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3167.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3169.jpg
Had our new apprentice started today, while I cut out the hole in the second seat bracket, Mike got started on punching and drilling holes for plug welding the passenger bucket seat bracket...
http://i5.photobucket.com/albums/y16...5/IMG_3186.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3187.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3189.jpg
After I got the bracket hole cut out, E media blasted the brackets and added some SPI epoxy using a brush. We mainly wanted to get the bottom side well covered as it will be inaccessible once welded in place..
http://i5.photobucket.com/albums/y16...5/IMG_3190.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3199.jpg
First coat...
http://i5.photobucket.com/albums/y16...5/IMG_3201.jpg
Two coats, that should hold us for under a seat...
http://i5.photobucket.com/albums/y16...5/IMG_3214.jpg
Meanwhile I got out the John Deere rod bender to see if we could make up some anchors for the shoulder belt..
http://i5.photobucket.com/albums/y16...5/IMG_3202.jpg
Bent with relief for a 1/2-13 lock nut..
http://i5.photobucket.com/albums/y16...5/IMG_3203.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3204.jpg
Welded with short bursts and plenty of cooling between to keep the nylon lock intact..
http://i5.photobucket.com/albums/y16...5/IMG_3205.jpg
test fit...
http://i5.photobucket.com/albums/y16...5/IMG_3208.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3209.jpg
plug weld holes drilled and welded in place....
http://i5.photobucket.com/albums/y16...5/IMG_3210.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3211.jpg
Mike finished up plug welding the seat bracket in place...
http://i5.photobucket.com/albums/y16...5/IMG_3213.jpg
More awesome work. I really like the tool and idea on building that retainer!
The hoop on the back adds strength (in my mind :LOL:) and keeps someone from putting a longer bolt through the side of the car down the road...
Had a late start in the shop tonight as I had to go look at a school bus. Yeah, week and a half to go until the end of school.
Looks like something gave the spot mirror a nice push..
http://i5.photobucket.com/albums/y16...0/IMG_3217.jpg
http://i5.photobucket.com/albums/y16...0/IMG_3218.jpg
The mirror mount looks like it's no longer straight....
http://i5.photobucket.com/albums/y16...0/IMG_3219.jpg
OK, so we found it hard to fathom something hitting the mirror that high in the air as the bus was driving into it, so the other possibility was something backed into this one.. A quick search of the buses parked close by revealed this one with some nice shiny metal showing...
http://i5.photobucket.com/albums/y16...0/IMG_3220.jpg
http://i5.photobucket.com/albums/y16...0/IMG_3221.jpg
A quick test drive showed that the mirror didn't vibrate/move around that much so we're going to address this after school is out so this one can still be used for the next couple weeks..
Back at the shop, time to weld in the seat retainer brackets...
https://www.youtube.com/watch?v=o9Gj...ature=youtu.be
http://i5.photobucket.com/albums/y16...5/IMG_3225.jpg
http://i5.photobucket.com/albums/y16...5/IMG_3226.jpg
....and then started the next shoulder harness anchor bracket....
http://i5.photobucket.com/albums/y16...5/IMG_3233.jpg
Fun how stuff happens and the driver doesn't report it or may truely be oblivious, hmmm!
Yeah, driver amnesia happens a lot where I work too. We had over $150k worth of unreported accidents last year alone among 100 trucks at 2 different locations. Crazy how these people keep their jobs.....
I hate you as usual for making it look so easy, :LOL: nice work as always.
Let me guess. You guys probably fix fiberglas as good as you do metal work!
Well.. I guess another lesson is at hand, I'll sharpen my pencil! :LOL::LOL: