I'm about to kick off the project of replacing the soft plywood floor in a 95 Carpenter. This isn't a project for my employer, this one's for a friend.
Anybody ever done this job before? Any recommendations for material to use? Anything at all you'd like to share about this job?
First off it *****. We've done many. I have some posts over on Facebook on the school bus mechanics page. You'll need 8 sheets of 1/2 treated. 2 10 yard rubber and 1 ribbed center if you doing it back for a bus. We used screws from Home depot to put hold that plywood in. # 21380. They are #10x 1 7/16".
Make sure to use correct size drill bits when drilling holes out and make sure you have extras. I also would prime the plywood on both sides and seal it as your laying it down. If your going to spend the time and money you should take the extra step or two and do as much preventive measures you can.
It's in surprisingly good condition for what it is. Seat bolts are in better shape than my 2002-2010 Blue Birds which makes me sad to think about.
I have a couple areas where I am going to have to repanel the floor and weld in some cross member repair kits. If it was going to be hauling children, I'd refuse to work on it and recommend it be scrapped. Since it's for hobby use (don't ask) it's good enough.
I have done many rebuilds about twenty or so. I would recommend 5/8 marine grade plywood. I would also recommend removing the body from the frame and have some full length stringers made out of 14 gauge galvanised steel and bolt them to the floor. Make sure you drill out the stringers for hold downs before you bolt the stringers on. I would most certainly prime the plywood or the rubber mat won't adhere properly and it will bubble up if not primed. I use Kilz brand primer. For the seat bolts that don't come through because they are inside of a cross member or whatever, just use lag bolts with lock washers were needed. Good luck too you.
Brian
Brian Prochazka Bedford City Schools Transportation Specialist
Plywood floor replacement
Posted - 02/27/2018 : 12:40:46 PM
