Category: RustlessMoneyPit

Alternator compartment
1. Inspection of the Alternator Compartment proved that all the wiring had been over charged, charging cables were brittle from overcharging and all wires had been damaged and were unsafe and undependable to use.
2. Ice picking of all framing in alternator area probed that framing was completely in need of replacement and very unsafe since it is part of the structural framing of the engine area supporting a 2500 lb. motor.
3. Deck and framing removed, rebuilt and reinforced as well as new tubing bumper.
4. 200 amp alternator installed with internal voltage regulator, all new cables installed for the new alternator.

Radiator Compartment
1. Inspection of the area found to be extremely rusted from the door entrance to the engine cradle.
2. Severe main Engine cradle & structural framing rotted and rusted all out within sight.
3. Removal of the radiator showed more horrible rust consumed the bus!
4. Use of house water in the radiator by previous owners caused the radiator to be deteriorated from calcium build up etc. The radiator proved to be worthless!!
5. The engine main cradle rusted out over 50% of height of 4 inch. Frame.
6. Piles of rust accumulated over the years in the wheel rim area.
7. Many weeks / months needed to plan all repairs and rebuild of the main framing of the bus.
8. All framing replaced, reinforced and painted.
9. Radiator disassembly was a bust, there is no area of the bus radiator that is reusable.
10. New engine access entrance door fabricated as well as new doors for tail lights and lower alternator door.
11. New design radiator door with adjustable air catching louvers fabricated and installed.
12. Old left side battery door compartment modified for new air dryer, new power steering pump reservoir.
13. New engine cooling and engine fume pushing fans installed at 45 deg. Angle in engine compartment.

Drive Wheel Compartment
1. Removal of outer skin from the bus shows views of rust galore, rotted framing and more rust.
2. Much of the drive wheel well framing had to be removed, reinstalled and reinforced.
3. Inspection of the torsilastic shackle on the right side of the bus was completely destroyed by rust and road debris and had to be replaced.
4. Much of the main structural framing of the bus had to be removed and replaced at one time which took months to do with much planning. All metal framing removed using 4” grinder using 6” grinder wheels. No torch was ever used!!

, left side of bus after pressure washing undercarriage.
1. Left side of bus rusted out, Drive wheel area needs serious frame rot, the main air tank for air brake on drive wheel is leaking with air from rot of the tank, and the air brake system between the drive wheels is so contaminated it is impossible to see any of the valves required for a operating air brake system.
2. Cables and wires, some with 12v in them are laying all over the bus frame air system compartment.
3. All the wheel wells inner walls are rotted out with holes you can put your hand through.
4. The dirt & debris in the air brake system compartment is in need of massive clean up.
5. Outer bus skins removed and need complete replacing after repairs done to outer framing of bus.
6. The right side of the bus in the drive wheel area torsilastic tube shackle needs complete replacement from rusting out on the inside, this is an important part of structural support for the drive wheel axle.
7. Rebuilt & reassembled the right side torsilastic shackle on both ends of the torsilastic tube.

Duplicate damage to framing as in Video #10.
1. Outer skins removed to expose more rusted out framing under skins needing replacing.
2. New wheel hoops of 1 ½” tubing rolled to diameter needed to fill the outer void of the bus frame and all of all wheel wells were done the same way. New hoop welded in place becomes an important part of structure framing when done.
3. Cleaned the wheel rims, installed them in the outer frame of the bus in wheel well, caulked them inside and out to seal out any rain moisture getting between the frame and hoop ever again.

Removal of fuel tanks
1. Unbolted fuel tanks, removed through the opening of baggage compartment allowing removal of fuel tanks with much finagling.
2. Removal of Boogie wheel exposed rotted framing this gets replaced and double framed.
3. Tried to remove the boogie wheel torsilastic tube without damaging the tube framing but this was not possible as it was rust-welded together. The torsilastic tube assembly had to be replaced, as usual.
4. After purchase of new / used boogie wheel torsilastic tubes, they were cleaned, disassembled, lubricated and reinstalled using my engine hoist as a lifting device.
5. The fuel tank storage area was completely reinforced, walled up and insulated against debris etc. ever causing damage to the fuel tanks again.
6. Wheel wells for access to fuel tanks have access panels on both tanks to get to wiring and plumbing when needed.
7. New smooth siding installed on the bus frame in place of fluted siding.
8. All areas of drive and boogie wheel area primer painted.

, left boogie wheel well.
1. The left side boogie wheel arbor has serious cracks, all rusted out and no good. Has to be replaced, removing both of them much damage was caused to tubes making them useless and needing replacement.
2. The center of the bus has a hidden space located from the aft baggage compartment that will house my Gray / Black waste water tank that I will have to fabricate.
3. The #1 air supply tank is welded, over and over and over which obviously leaks and needs replacing.
4. Serious build up of rust in wheel well framing cavities from being open to dirt and debris.
5. All framing in the boogie wheel well area was replaced, reinforced and painted.
6. Photo of how I enclose the underneath of my bus against winter weather so I could continue working during the winter.
7. The left boogie wheel is completely repaired and reinforced and painted and has an assembled aluminum access door to the fuel tank.
8. The new boogie wheel torsilastic tube installed in the bus frame after fitting using my engine hoist.

Left Drive Wheel well
1. Left drive wheel well inspected for needed repairs and painted.
2. A new air tank was installed in the New Air Brake Valve system compartment between the drive wheels. This area houses all new air valves for the use of Spring Brake cans in place of the DD3 Eagle Brake design. It took over 2 weeks to install all new valves and place and label them where they work properly.
3. Aluminum access panels cover all 4 air tanks newly installed in the bus, protecting them from dirt and debris forever.

Baggage bay doors fabrication.
1. Aluminum baggage bay doors and outer supporting frames all rotted from water getting behind the outer bus skins.
2. All baggage bay doors were removed, prefabricated with new design to make them open higher but using some of the hardware from my old doors was important to keep some of the Eagle design.
3. All doors were double skinned with insulation in between to control noise and temperatures in the baggage bays.
4. Vertical outer framing door supports all rotted and needing replacing. When disassembling the outer frames large deposits of rust were inside of the framing.
5. After all needed outer door framing was completed, the new doors were fabricated and installed with much difficulty all alone.
6. Doors now raise higher making getting inside the baggage bay easier, I need to get new door shocks when possible.
7. New baggage bay doors skinned and primer painted.

Front wheel well.
1. Front wheel area housing the framing for the front torsilastic tube support and baggage bay flooring all replaced, flooring increased to 7 1 ½” tubing frames the entire length of the baggage bay floor with a cross member support also tied into making this stronger.