I've spent the past month concentrating on rebuilding and painting all the windows. The 4104 has a total of 26 windows. A split windshield, which I installed last year (2), driver's side window and matching door window (2), "Big D" windows (2), side sliders (14), "Little D" windows (2), emergency door window (1), rear center window (1), rear side windows (2). The guys at Battle Creek Glass cut all but the windshield using old glass as templates. We chose medium gray tint 1/4" laminated glass. Battle Creek Glass, did a fantastic job cutting all the curved lines.
First step, remove all windows and
disassemble. One Slider assembly has the main frame, two window frames, and a center brace. In addition, there are rubber seals around the main frame and each pane of glass, and a whole lot of old silicone caulk used over the years to patch leaks.
After disassembly, the seven large frames went for soda blasting to completely remove all paint other crap. The remainder of the parts were sanded to bare metal. All the window parts were then primed with self etching primer, followed by two coats of fill primer, then a light dusting with black as a guide coat. The guide coat will tell you where the low spots are. Then the fun begins. Every part is wet-sanded with 600 grit until the guide coat is completely removed and the piece is smooth withno visible defects.
So, the assembly starts with putting a rubber seal around the glass. Then the glass is dropped into the curved part of the slider frame and the back side of the frame is screwed on. Repeat 14 times. Next two sliders are inserted onto the main frame on the slider rails. Next the frame brace is screwed on. Repeat seven times. The five remaining fixed windows were assembled similar to thee slider frames. 
Next step - hang the large slider windows on the bus via three hinges each. Install the fixed windows by screwing into window openings. The only remaining step is to apply tape-backed window seal around the big slider frames. All the windows will have to come out to paint the bus, but we're going to the Flint bus rally the end of August, so we need windows in now. Plus it's the best way to store them and keep the bus closed to the weather.
How much minus all the labor did the project cost you? Looking to do something similar to my pd-4106. I want to keep the rv looking like a bus similar 2 your project
ReplyDeleteCameron,
ReplyDeleteSoda blast frames $250
Paint and supplies $75
All new window glass $1700
Rubber seals for glass $80
Frame seals $300
Slider seals $330
I got all rubber seals from Trim Lok at http://www.trimlok.com/
Did you find rear center glass? If so where? Trying to locate one for my project
ReplyDeleteI have all three pieces. One side piece has a crack in one layer of the laminate. The center glass is intact, but is foggy around the edges. About a good as you're going to find these days. This is one of those unobtainium parts. Where do you live>
DeleteAnnville PA (near Hershey)
DeleteAnnville PA (near Hershey)
Delete,I am looking for window rubber for a pd-4103 does anyone know if this is standard rubber by the foot and where I could find it!
DeletePs. I plan on visiting hershey and carlisle this year to obtainium stuff. ;)
,I am looking for window rubber for a pd-4103 does anyone know if this is standard rubber by the foot and where I could find it!
DeletePs. I plan on visiting hershey and carlisle this year to obtainium stuff. ;)
geo,
ReplyDeleteAre you talking about the seal between the glass and the frame it held in, or the seal around the outside of the whole window unit? If yours are built with the window sliding in a two pane frame then I might have sources for both.
sweet, both! Bus getting quite wet here in oregon :( what is your email or #? mine is wingeorge@yahoo
Delete