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11-13 Re-Do: Sealing School Bus Leaks Again

With all of the rain Central Texas has been getting, it really has allowed us to get some realistic ideas on if we did a good job with our caulking & foam. Leaks, Leaks, Everywhere!! Ok, they are not as bad as they once were. Since re-sealing the windows, roof, and sides; the leaks have been minimal…but still…I am ready to build. But, first things first…Where oh where could they be coming from…

Not what I wanted to see..LEAK 1
Not what I wanted to see..LEAK 1
UGH! LEAK #2
UGH! LEAK #2
Last One..Leak #3
Last One..Leak #3

Time to inspect. They were only on the passenger side of the bus, and it felt wet in the corners of the windows. There were wet spots on the ceiling on the left side only….

Some of the leaks are coming from the corners where the Great Stuff is.
Some of the leaks are coming from the corners where the Great Stuff is.
From the outside, I squished a piece of the Great Stuff and water came out like a sponge! It is definitely not fixing the leak problem..
From the outside, I squished a piece of the Great Stuff and water came out like a sponge! It is definitely not fixing the leak problem..

Lesson #24 in Bus Renovations…Don’t use great stuff on the outside of the windows. Solution? Darn tootin.

Apparently, it was absorbing water amd making its way through our newly sealed windows…I THINK NOT! We scraped the foam off on the outside only, and used the 2 in 1 Premium Polyurethane (used on the windows) to really gob up the corners.

Def learned we are not professional caulkers ;)
Def learned we are not professional caulkers πŸ˜‰ But, I don’t see any holes!
I do think that this will prevent any more rain or water from entering.
I do think that this will prevent any more rain or water from entering.

Next after fixing the windows, I needed to make sure the roof was leak proof. Completely leak proof. Or at least as close as I could get with my experience πŸ™‚ The only thing I had not sealed yet was every single bolt and screw. I did the seams and a few of the bolts that looked “rough”. So, I headed back up to the roof and finished the job!

Using Premium Polyurethane (same as on floors) to cover each and every bolt/screw on this god forsaken roof!!
Using Premium Polyurethane (same as on floors) to cover each and every bolt/screw on this god forsaken roof!!
Using the last of the 2 In 1 Premium on the side roof bolts after running out of my other polyurethane.
Using the last of the 2 In 1 Premium on the side roof bolts after running out of my other polyurethane.

Ok. Final Drum Roll Please……..

I think this did it. Fingers crossed this did it. I really really hope this did it. LOL. Whatever, live and learn! I will keep everyone posted on if this fixed it! Since we are supposed to have great weather next week I think I will use the hose to find my leaks…ready to tackle and end this beast.

(***UPDATE 2019, POLYURETHANE and PAinting touch up paint on the body and rolling paint on the roof of the bus helped seal it. We have not had any leaks from the roof that we know of. We also check the roof every few months and caulk where it looks like it is cracking.)

At the end of the month (June 2015) we should be heading to get the electrical stubbed out, and then we will begin building…I hope!!

More Coming Soon….

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11, Part 2: Skoolie Window Removal/ReSeal & SIde Wall Demo

STAGE 11: Remove Windows/Side Panels & Insulation, Re-Seal and Replace Windows

Part 2-Day 2

The next day I was certain we would not get to complete our project because of the rain. The Universe was looking out for us though because by 3 PM it was clearing up. So, we all got to work on other side of ChittyBang!

We removed the windows successfully! The guys started in on the side panels, while I worked on cleaning and scraping the windows.

JB removing fiberglass leftovers with the wire brush on the drill.
JB unscrewing the panels and Crab confidently cutting the panels off at the top.
My littlest Crab hammering stuff.  It was cute for a little while, but then Mommy's ears needed a rest :) She helped me spray the windows off and get some of the screws ready for the windows.
My littlest Crab hammering stuff. It was cute for a little while, but then Mommy’s ears needed a rest πŸ™‚ She helped me spray the windows off and get some of the screws ready for the windows.

The Panels were removed much more smoothly on Day 2 πŸ™‚ We got everything smoothed out on the frames, the insulation totally removed, the windows cleaned and scraped…now for the last stretch!

Scraping the old caulk off of the frames before Putting in the windows!
JB taking a break before Scraping the old caulk off of the frames.

Finally done!

Completed Door Side View!
Completed Door Side View!

We also put some caulk on the screws/rivots that were on the walls under the windows to make sure no water was coming in from here. Some insulation was wet, so we needed to be sure there was little chance of any more leaks. We are not professional bus renovators, so we do what makes sense to us as we do it. I want ChittyBang as leak proofed as possible πŸ™‚

We are finally done with demo!!!

Now onto foaming, and re-sealing the roof and side seams!!

STEP 12

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11 Part 1: School Bus WIndow Removal and Re-Seal

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.
Before window/side panel/side insulation removal.
Step 1: Take out windows!
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 :)
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 πŸ™‚
Long Shot of the Guys working. Keep on cruising, keep on cruising :)
Long Shot of the Guys working. Keep on cruising, keep on cruising πŸ™‚

Windows out, screws out…..now how to detach the tops???

Attempt #1 of Removing Panels: Drilling a hole through each joining point. FAIL
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
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 :/
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.
Attempt #3: Crab cutting with the angle iron and diamond blade attachment from the top.
SUCCESS!! Close Up of cutting action
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.

Using the grinding wheel to remove any metal shards and smooth out the top.
Next, Crab used the grinding wheel to remove any metal shards and smooth out the top. Notice the completelyΒ  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!
The old windows awaiting a spray of the hose and a good scraping!
Hose sprayed Windows awaiting sealant!
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.
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!
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.
Putting back the first, freshly scraped and sealed window.

Man, time flew by…

About 1 million
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 :)
Finishing up day one. Picking Up and messing around. JB was playing with Dex, who loved jumping into ChittyBang to watch us work πŸ™‚

Coming up next is Day 2: Stage 11, Part 2

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