Welcome to Phase 1! This section documents how it all started, the initial state of the bus, and the work done to prepare the floors and wall panels for the build.
This phase was important because its the foundation that the rest of the build will be built upon.
I took it kind of easy this weekend, I did manage to remove the rest of the wall panels and insulation. I took the wall panels to the scrap yard, and I worked in my garage to reclaim a 10/100 Box, 6 outlets and wiring that I will use on the Bus. I had put it in my garage about 20 years ago but never ran a main line from the house out to the garage so all this hardware was just sitting out here doing nothing.
It’s Friday, it’s cold, and my body is begging for a break. So I went shopping at an RV store, grabbed a catalog, and a set of leveling blocks. I did manage to cut out more of the side walls and grind down and prime the rear bumper last night before the sun went down.
Very productive weekend! I removed the heaters and rerouted the lines so coolant will flow from the Radiator to the Engine.
I also removed the side panels on the passenger side of the bus while Caden wrapped up the welding of the trouble areas on the floor.
Additonally, I bought and wired three new batteries and the Bus started right up.
Got an Early start this weekend. I had a ton of things to accomplish.
I loaded up the van with the old Seats and a bin of scraps. I took it to the local dump. After that I tested the old batteries that I had charged and stored indoors over the winter to see if they were holding a charge (they did not hold a charge.)
So I travelled to two Autozones to buy new batteries, each location had 2, I needed 3. Recycled the old batteries and hooked up the new ones and grabbed a little diesel fuel to ensure I had some fuel in the tanks for when I get the engine started.
Once I got the batteries hooked up in the tray (I cleaned and primed the tray beforehand (sorry no images or video of that, just trying to brush as much as possible while I had a usable brush…Chassis Saver leaves the brush useless once it cures.)
The Bus started right up!
My next project was to remove the rear and mid-ship heaters from the bus and reroute the antifreeze lines to ensure the radiator and engine flow of coolant was maintained.
This job I anticipated would take a while, but it went surprisingly well.
My Son Caden stopped by and did some practice welds, once he had the machine dialed in he tacked metal over one of the problem areas near the wheel wells. Day light eluded us, so tomorrow we will try to get the remaining holes patched with steel.
It was a busy weekend!, I went to Harbor Freight and picked up a flux core welding setup, some 16 gauge steel, and my Chassis Saver finally arrived. Not knowing much about welding I did some practice welds, I am not ashamed to admit I hate it with a passion. Anyways, Once I get better at it I’ll get the holes patched up, but I need to get better at welding first before I try welding onto the bus itself. I did more rust removal and a lot of shop vac and sweeping. Then I moved all my tools form the back of the bus and put down the Chassis Saver to see how it would cover, it was worth the $120 a gallon, I credit Chuck Cassidy for that tip, and for the way I will be doing the floors as I get to that part of the build. I may drop a link here to one of his videos here and there so you can see how I am planning to do my floors.
So as I said earlier, I am still learning the welding, need more practice before I try to patch the holes, I decided to get some of the Chassis Saver applied, it covered great and really was worth the investment.
I was able to remove all the screws from the floor, I moved the stock heaters up front out of the way to make it easier to prep the floors. Next I need to wrap up the rust removal, and weld a few problem areas before priming the floors with rust encapsulation.
This was taken by the previous owner of marketplace, not bad progress for a weekend project!
Today I started prepping the steel floors to remove the rust so I can prime them. I discovered several screws that were stuck into the floors that were fasteners for the wooden floors that were already removed. So I grabbed a grinder, and a barrel sander and got to it.
Today I removed all the seats and panels and parts that were sitting inside the bus. I stored the things I am hanging onto, and then I swept the floors and loosened some rust and dust and old wood/screws/brackets and other debris.
The first thing I had to do is invest in some tools. I bought a table saw, jigsaw, an oscillating tool, and various bits/blades. It was Christmas so I put them under the tree for me and the boys.
One of the big reasons I wanted to do this project is to learn and teach my kids how to handle tools and make things. Two of my sons are school aged while the other 3 are grown and in their own careers.
Hoping this will be a great. Bonding journey for all of us.
The Sickler Skoolie Build 