So far, the two essential tools for getting rid of the rust seem to be an angle grinder with a paint stripper wheel and a cutting wheel. If you can’t grind it out, cut it out.
The roof rack was a surprisingly bad area. Since we had stuff and/or a tarp up there for 4 years, it seemed to be a spot where moisture could accumulate and linger. And, all the stuff bouncing around and scratching up the paint probably didn’t help. A perfectly-sized roof box would be the way to go next time, so I’ll be searching for something. If anyone knows of an existing product, please let us know.
Complicating matters is the rain. I can spend hours grinding out the stuff, then it’s back the next day after wet night. Incredible. But, on the whole, things are moving forward. It’s just frustrating. And, I just keep finding more to do.
I think my biggest issues have been corrosion from the inside out. The entire floor area only had surface rust from the underside. The interior was the big mess.
I think every time we piled into the bus during a rain or spilled water on the floor when filling our sink (every time, basically), a little bit more went under the flooring and just sat there rusting away. It was still wet when I pulled the floors out and the wood was rotten. The best prevention is keeping the bus dry on the inside, I suppose. We’ll be going with linoleum flooring this time around to try to keep the water out.
The infamous windshield spots were bad enough to let water inside and rust out the edges of the dashboard! Cut and weld. I’m getting better with practice…
And, unless someone objects, this will be the last post featuring photos of rusty metal. I hope.