Bus crash damage - assessment - PLEASE READ

MikeWhitney · **Joined:** Wed Aug 20, 2003 9:15 pm **Posts:** 4724

Those of you who were not at the meeting may not know - While bringing the bus back from Wilson, Ryan drove the bus under a low bridge, and some damage was done to the roof and PA speakers.

I just got in from assessing and prepping the affected areas. The damage is a little worse than originally thought.

- entire roof of the bus scraped up - superficial
- top emergency exit is broken beyond repair - easiest course of action is to replace
- all 4 PA speakers destroyed - need to be replaced
- front top seam has been partially ripped off - minor gap remains - repairable
- rear top seam completely torn off - large gap - needs repair ASAP
- rear cap fiberglass overlap cracked in 4 places - short (2-3") cracks
- one rear AC mount bent - bolts bent, holes torn in roof - repairable

The emergency exit was a PITA to remove - took 1 1/2 hours - was held on with 20 HD rivets, sealer, and caulking. The rivet shanks still need to be removed.

Most of the can be addressed right away if we can get materials in hand ASAP. I NEED SOME VOLUNTEERS to come and help THURSDAY PM starting at 6pm. Here's what needs to be done:

MATERIALS - NEED VOLUNTEERS TO GET
-----------------
Replacement PA speakers - Available at Garner Radio Shack
Auto seam sealer - at least 6 tubes (Advance or Autozone should carry)
1/2" wide aluminum strip - need 10+ feet
Box of 1" screws to attach aluminum strip
NEW emergency exit vent - can we get something Fri? - Charlie Guthrie looking into it
USED emergency exit - CAN SOMEONE DO SOME CALLING AROUND?
Fiberglass repair - anyone have expertise or a kit?

TO DO THURSDAY - LET ME KNOW WHAT YOU CAN DO
----------------
Emergency Exit hole
- Remove 20 rivet shafts
- Plan/fabricate temporary hole cover and install
PA speakers
- Wire new speakers 2 parallel, 2 series
- Attach banana plugs
- Remount to aluminum plate (survived)
- Temporary attach of emerg exit trim plate (receptacles)
- Attach plate to temporary hole cover
Front seam
- Clean up loose seam sealer and damaged strip
- Cut and install new aluminum strip w/ 1" screws
- Seal completely
Rear seam
- Clean up loose seam sealer
- Reseal open gap with seam sealer (or other mat'l?)
- Cut and install new aluminum strip w/ 1" screws
- Seal completely
Rear fiberglass
- Patch fiberglass or seal with seam sealer
Rear AC mount
- We have the option of just sealing the big holes and leaving it
- Cut away seam sealer over top mounts
- Remove AC cover
- Remove (bent) bolts and detach unit
- Repair broken fiberglass, patch holes
- Reinstall with new bolts
- Seal top brackets completely

Not exactly what I was planning to do tomorrow night. It's a bummer, but we can get it back in shape. This is urgent because we were planning to leave the bus at Kevin's or Bret's and taking it from there to L'burg. After L'burg it is expected to go to a new storage home. The top of the bus will leak like a sieve right now and cause extensive damage. So reschedule your plans for Thursday and help your club.

Thanks
Mike

Ryan Holton · **Posted:** Thu Mar 10, 2005 8:40 am

First off, I deeply apologize for messing the bus up. I had no idea, that the bus was that tall. I am not very familar with the Bailey area, and I didnt know of any other way out to 264. I feel even worse for the fact that I cannot easily get up to Raleigh to help fix my screw up.

Feel free to tar and feather, tie a rope to my leg and drag me about Laurinburg or just slap me upside the head in general.

Sorry :cry:

Ryan Holton · **Posted:** Thu Mar 10, 2005 8:56 am

MikeWhitney wrote:

Replacement PA speakers - Available at Garner Radio Shack
Auto seam sealer - at least 6 tubes (Advance or Autozone should carry)

I will check the New Bern Rat Shack and see if they have some horns and I will pick up the seam sealer.

I have made arrangements to be at Mike's around 6-6:30. Hey, I have to at least try to fix my mistake.

Scott Johnson · **Posted:** Thu Mar 10, 2005 9:04 am

Ryan- No need to feel bad about going out of your way to help the club. Shit happens.

I'm more concerned with the people that just pay their does and don't do anything else.

Scott

Jason Mauldin · **Posted:** Thu Mar 10, 2005 9:19 am

scottjohnson wrote:

Ryan- No need to feel bad about going out of your way to help the club. Shit happens.

Ahhh, come on! We can't let him off that easy! :lol:

Vincent Keene · **Posted:** Thu Mar 10, 2005 10:40 am

FYI, I talked to Randy this morning. He said his Dad's shop has done these type repairs MANY times in the past (Ryan isn't a "bus-convertible" pioneer) and can help if we need him to.

Vincent Keene · **Posted:** Thu Mar 10, 2005 10:42 am

Ryan Holton wrote:

Hey, I have to at least try to fix my mistake.

So when will you have time to re-paint the bridge? I hear the town of Bailey doesn't want it to be white underneath their bridge. :wink:

MikeWhitney · **Joined:** Wed Aug 20, 2003 9:15 pm **Posts:** 4724

Update:

Horns: Ryan - if you can't find them in NB, I KNOW Garner has them in stock. If you cannot get them here by 6:30, I need to know ASAP to find another volunteer.

Auto seam sealer - Ryan

Chris Brown says he can come by at 8pm.

Scott will come over at 6pm. He is going to pick up some supplies.

Ron says he can come if we need help.

I could still use someone to quickly check for a used emergency exit vent. We will probably have to go with something else temporarily.

Ryan Holton · **Posted:** Thu Mar 10, 2005 12:42 pm

MikeWhitney wrote:

Update:

Horns: Ryan - if you can't find them in NB, I KNOW Garner has them in stock. If you cannot get them here by 6:30, I need to know ASAP to find another volunteer.

According to the net, the New Bern store has the horns in stock. Also, since I am leaving from New Bern, I will go thru Garner, so I can stop there if needed. I should have horns in hand by 1 pm. I will post an update when I get back from lunch.

Ryan Holton · **Posted:** Thu Mar 10, 2005 2:39 pm

I have 3 horns and sealant (5 tubes 3M Clear Silicone) in hand.

See you guys at 6-6:30

BTW- Good job on the Avatar, I was waiting for something like that. :oops:

MikeWhitney · **Joined:** Wed Aug 20, 2003 9:15 pm **Posts:** 4724

OK looks like we're in good shape between Scott, Ryan, Chris B later, and Rick B later. I'd still like someone to take on the speaker wiring since I have other things to work on but we can manage.

Rick B got sealer tape, aluminum strips, and plastic cap strips
Ryan is bringing the horns
Scott is picking up screws - and Scott I need you to find some temporary weatherstripping for the temp hole cover.

Charlie G is ordering a new hatch, be here next week. It would have cost $120 for overnight shipping. So we need to make a temporary hole cover. We can find something in my garage for a temporary hole cover. Replacing the em exit hatch is still the easiest and most functional option.

See yall tonight.

MikeWhitney · **Joined:** Wed Aug 20, 2003 9:15 pm **Posts:** 4724

Everything went very well tonight and I'm happy to report that the bus is mostly repaired, thanks to everyone that stepped up to the task.

- Front seam strips replaced, caulked with butyl rubber, and capped with plastic trim
- Rear seam likewise repaired
- AC mount repaired
- Temporary plywood hole cover installed
- New PA speakers installed and rewired

Might sound like an easy task, but it took 8 people 4 hours! I will never again underestimate how long it takes for "custom fabrication" after dealing with all the work on the bus!

Thanks to the following folks who came out - Carl F, Art M, Dustin and Malia, Chris Brown, Ryan H, Scott J, and Rick B.

I also took care of a few nagging issues -

- New "quiet" front table holders installed - Toggle clamps kick ass
- Both deep-cycle batteries tested bad and were sent to the battery graveyard
- Replaced accessory battery with one of the 13-year-old Optimas that came with the bus and tested fine
- Retightened hitch ball (crappy impact gun!) - it was probably the source of some clicking/popping that was happening
- Retightened hitch bolts - ditto
- Added shim to the receiver tube - lots of play
- Charging up spare "loose" Optima battery
- Scott put the "Remote PA speaker" into the trailer

After I charge the loose battery and put it back in the trailer, the rig is ready to roll. I plan to be on site at the Rallycross by 8:15 Sat AM.

See y'all at the rallycross!

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Bus crash damage - assessment - PLEASE READ

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