STAGE 11: Remove Windows/Side Panels & Insulation, Re-Seal and Replace Windows
Part 1
After much deliberation, we decided that removing the side panels and resealing all of the windows was the best route for us to take instead of starting the floor framing. A few reasons we decided to are:
1. We found some leaks and knew the windows were partly to blame.
2. If there were leaks, how far into the insulation under the panel did it get? Needed to know this answer.
3. We gained a couple of inches by taking them out and replacing it with better insulation and wall paneling, rather than just building over it.
4. We already demo’ed an entire bus, why stop here?
5. Windows are expensive to replace. And we would need a lot of windows. So, resealing seemed wise for us until we can replace some.
6. I needed to know that this bus had no leaks or hidden rust damage. That is just a personal preference.
In Texas (and most of the US), the last few weeks have given out a lot of rain. This prevented us from moving forward in the next step of our project because we had to remove the windows to complete it. Finally, we had a break in the weather one afternoon and some help from our Missouri friend, JB, and his dog, Dex, so we decided to go head first and figure this beast out.
DAY 1
Before window/side panel/side insulation removal.
Step 1: Take out windows!
Step 2: Unscrew Panels
We were so lucky to have JB over for the weekend to hang out! I immediately put him to work unscrewing the side panels with Crab lol 🙂
Long Shot of the Guys working. Keep on cruising, keep on cruising 🙂
Windows out, screws out…..now how to detach the tops???
Attempt #1 of Removing Panels: Drilling a hole through each joining point.
FAIL
Attempt #2 of Crab Removing the side panel: Cut it off below the window bottom frame with an angle grinder and a grinding wheel.
FAIL
It did cut this panel off, but we would have blown through a lot of those wheels if we continued 
We also removed the insulation from the walls. Some pieces were damp on some areas, but no rust was on the wall….PHEW!
Attempt #3: Crab cutting with the angle iron and diamond blade attachment from the top.
SUCCESS!!
Close Up of cutting action
We also used the metal brush on a drill (used for removing rust) to remove the left over fiberglass remnants.
Next, Crab used the grinding wheel to remove any metal shards and smooth out the top. Notice the completely insulation free wall:)
We also scraped the old caulk off of the sides of the window frames on the bus to give the new seal its best shot.
Well, I can’t be standing around all day taking pictures so…meanwhile outside of ChittyBang….
The old windows awaiting a spray of the hose and a good scraping!
Hose sprayed Windows awaiting sealant!
The Product Used:
LocTite PLS40 Polyurethane for Windows is what I wanted to buy for the windows. We used polyurethane for the holes on the floor and I really liked the way it worked and its specs, I am hooked. My local HD only had 1 in stock, so I bought it.
Along with 5 bottles of LocTite 2 in 1 Premium Polyurethane. This is what we re-sealed the windows with. Great reviews! the PLS40 had great ones too. I am definitely a fan of polyurethane!
For the next part we had a pretty good system going. Crab was on a step ladder outside with some LocTite 2 in 1, and JB and I were inside re-sealing each window. Then the window was place back into its frame.
Putting back the first, freshly scraped and sealed window.
Man, time flew by…
About 1 million “caulk” jokes later, and we have One Side removed and all of its windows re-sealed and replaced!
Finishing up day one. Picking Up and messing around. JB was playing with Dex, who loved jumping into ChittyBang to watch us work 🙂
Coming up next is Day 2: Stage 11, Part 2
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Anything after this or is this as far as it went?
There is a part 2 and more articles after this one. Just keep hitting next at the bottom! I have not finished blogging on the whole build but our Facebook page @chittybangskoolie was consistently updated through the whole build with pics. I am working on a detailed walk through video now. Check us out on YouTube for videos of the completed bus on our channel @crabtree97 thanks for commenting!