How bloody frustrating is that?

Yup. It's a broken drill bit! Not a wussy little drill bit either. That's 3/16th! I'd been battling to install roller blinds where my existing stick-up blinds had fallen down. The problem was I had to drill through not just inner skin but body skeleton as well. That stuff is hard to drill through!

I'd installed two blinds and was working on the final hole for a third blind when - due to tiredness - I pressed the drill too hard and the bit snapped. Well, that put paid to what I intended to do today. I can probably put the third blind up but the end is secured by a single rivet not by two. Yes, today I was using rivets since I am now totally out of short self-drilling bolts. It makes no odds - the blinds will be pretty secure anyway.

My goal for the weekend had been to install all the blinds, finish installing the main breaker box, install the waste water tanks, fit a method of securing the boxes in the back closet and put a panel over the lower back window. Well, that schedule just got knocked for six! Drilling holes today was such a beastly task that even with a power drill it has taken several hours.

Then, of course, there are all the tools I cannot find since I tidied the bus up and put everything where it is supposed to be. I have to be ready for an inspection at any time to verify that I have a motorhome, not a bus. One of those things was the tool I need in order to change the grinding disk on my angle grinder. Thus the disk could not be changed and I could not use my angle grinder to cut the blinds as I have been doing. Instead I had to use a hacksaw. All stuff that just takes extra time!

Right now it's pollen season so everything outside is covered with pollen. Every footstep kicks up gret clouds of pollen - it's like walking on the moon!

The final window one one side put up the biggest fight imaginable. The drill was skidding all over the place. Talk about rock hard steel! Eventually I had one hole in situ. Then after a long hunt, I found just one solitary rivet. I ran out of rivets!

Still, the three blinds I put up look pretty good. There're two more to replace but oddly enough, those stick up blinds have not fallen down - yet. I expect they will if left up for very much longer.


So, tomorrow I definitely need to pick up more rivets. I don't think there's much danger of my proceeding further than putting up the other two blinds and installing the main breaker box.  I'd like to install the underbody waste water tanks and install something to control the boxes stored in the back closet. I have a vague idea that bungee cords might help there but anchor points will be the challenge.

Another thing I'd like to do is to replace the lower rear window or at the very least to cover it on the inside. I could simply bolt or rivet the cover over the window. Replacing the window would be the best option but also the most time consuming. There's an awful lot of welding involved there!

Tomorrow I could buy the stuff to mount my underbody tanks though I have a feeling it won't be needed or used for a while. I know I need to replace my CB aerial too.

Depressingly little achieved

Today was pretty much of a washout in terms of achievement on the bus. The blinds didn't get put up. The main breaker didn't get installed. Nothing really was achieved. I have no real excuse for that. I guess I really wasn't feeling too great what with the sudden hot day, the time change and general depression.

Despite all that, I did wipe down the power socket cover with paint thinner. Then it was sprayed with grey paint. If the paint sticks then the thinner trick works. As a control sample, another area where the paint was peeling was wiped down with thinner and sprayed. It'll be interesting to see if the thinner trick actually works. I have my doubts.

The old main breaker box, I cleaned up and removed the cables, rescuing the TT30 plug that was attached to it. The next stage was to bore a hole in one side that would accommodate my 3/4" cable sleeves. That was a challenge that took literally hours. The main cause of the slowness was that the tool was entirely inappropriate. Now the reason I used an inappropriate tool is that I make so few holes of that diameter that rather than spend $25 on the proper hole saw, I spent $7 on a cheap hole saw designed for wood. I simply use it for metal and regard it as disposable. So, the hole was bored upon which the rainspots that had been hitting me off and on for the past few minutes turned into a torrential downpour.

Retreating inside the bus, I pulled out a file and filed the hole to make it really work with the inlet. After the rain had drenched the outside world, I worked on the hole a little more with the hole saw. Then the inlet was inserted followed by the end of the 3 foot section of 8-3 cable that raised so many eyebrows in Lowes (hiss, spit). The other end will go into my sub panel. 

I never got as far as installing the panel. It was rather warm in the bus, hence my thoughts about a solar-powered extraction fan. I did have a go at installng a roller blind to replace the fallen stick-up blinds. Thus, I pulled out the battery drill and started drilling and drilled and drilled and drilled and made a small hole but not deep enough to achieve anything. At that point the light went so for possibly the very first time I put power through the inlet socket I installed and had light inside the bus powered by 120v mains power. That worked quite well.

I had a look for the vehicle registration documents but didn't find them in the obvious place. Clearly they much be somewhere less obvious. I need them to be able to send off to apply to have the bus retitled as a motorhome. To be absolutely honest, I think the insurance companies are being ridiculous on insisting on retitling as a motorhome just to insure everything. 

I put it off as long as I could...

Then I crawled or rather rolled under the bus to measure the space available for my battery compartment as being 13.5 inches. Then I set to work.

The first thing was to shovel the sugar I dumped from my abortive sugar blasting attempt away. Scooping it up in a shovel set hoards if wasps that had been clustered thickly over it, buzzing around angrily. Clearly using sugar has hazards!

For the next hour or so, the steel for the compartment was measured and cut. The space needed is only 7x11 inches per battery but the compartment will be 19 inches deep - just in case more space is needed.

The next thing was to balance it all together and I must say, it looks pretty decent. After that came the drilling and bolting...

The plan is initially to have a plywood floor on the compartment as it'll initially solely be a cable compartment. Later, I'll replace the floor with something more suited to batteries.

Looking at the cross members underneath the bus, they seem to largely be closed box section with a few c section beams. That's not very welcome as it looks like I'm going to have to get my box welded onto the bus. On the other hand, having it welded on means that at the same time, a stouter floor could be added, stouter sides and my sections could be tack welded for extra security.

I plugged on until I was overcome by mosquitoes and darkness. Looking at my construction it appears the steel of my angle bracket is not a true 90° as the steel section is slightly wedge shaped. Given this is steel from the bedframes the hillbillies installed, I'm not surprised its not quite right. Nothing they used or did was right. I'll plug on and see if I can at least get the front square. It really doesn't matter too much if the back is angled.

That's what it looked like when I finished work for the day. There are still several bolts to install plus lock nuts. I'll have to go over all the bolts with a wrench later, just to make sure everything is tight. It's looking like the bottom will be held on by between 24 and 32 bolts. The top will be held together by a similar number. I think I can defy 1000lbs of battery to cause that lot to sheer. The extra long bolts will be trimmed after the lock nuts have been installed.

I had a casualty. One of my 4.7mm drill bits broke. Perhaps I should say I broke it. I'd drilled through a metal section and the section moved when I was drilling through the second piece. Needless to say, the drill bit objected. Fortunately I had a spare.

Unless I can get a lot done tomorrow, this underbody compartment looks like it could drag on for a couple more weekends. Having said that, its getting ever closer to completion.

In Tractor Supply yesterday I saw some very interesting U bolts. Those could come in handy for my water tanks. That is, of course, if I can bolt through C or I section rather than box section.

I'm beginning to think that I might have to investigate welding. The same nuts on the bus forums advised against Harbor Freight gasless wire welders but then they never think much of non premium solutions. This is of course typical of forums!

After completing the basic compartment construction, the next stage will be to investigate attaching the compartment underneath the bus. I'm expecting to have to trim some of the girder sections. Honestly, I can't wait to be rid of the hillbilly compartment. Left to my own devices, I'd have simply not put an underbody compartment. If I'd had the bus straight from the depot, there are a few things I'd have done differently. One thing is, rather than simply laying plywood over the central walkway, I'd have removed the central walkway!


As it is, the floor has a slight arch in the centre because of the walkway. As it had to be removed as one section, I couldn't do much about it without ripping up the entire floor. Having said that, I suspect that might have been a better option.

What an awful disaster

Today was pretty much an unmitigated disaster from start to finish. Let's start from the beginning...

Overnight insomnia kept me from having a good nights sleep. Thus at 4am I turned my 6am alarm off. The result was that I missed my Tuesday morning voluntary job. Had I gone in after two to no hours sleep, I'd not have been all that great.

I went out to the bus after breakfast and found I needed to go to the store to buy a few things. Mind, I needed to get out of the house. This was my first trip in a week! My usual job has quit on me for the summer so its a case of not spending anything and minimising travel.

So, I went to the store and got most of the things I need. As usual Lowe's was totally out of 1/8 drill bits. After chasing down a clueless shop assistant who had made haste to bugger off when customers looked likje they were about to approach, it transpired that he'd never heard of carborundum drill bits or diamond tip drill bits. Clearly something too specialised for Lowe's.

By the time I'd finished at Lowe's, I was feeling the heat a bit because it was still over 100F outside. Thus, other things I needed never got picked up.

Returning to the bus, it was just too hot to work inside and thus I decided to work on patching holes. About 12 were just screw holes that I treated for rust and filled with a rivet. Four holes were larger requiring patches. Thus I found a suitable strip of aluminum and cut four patches with my angle grinder. Then I picked up the wrong piece of metal and burned my fingers.

Recovering from signed fingers I drilled a hole in the first piece of aluminum which broke loose from the mount, flipped around and hit my fingernail, breaking it. Cursing, I drilled a hole for the rivet in the bodywork. Then after I slapped silicone glue on the back of the piece of aluminum, I riveted the aluminum on via the first hole. While drilling the second, the drill skipped and the hole didn't end up quite where I wanted so the aluminum when held by the second rivet wasn't straight. The next hole started well enough by then my 1/4 inch drill bit snagged on the edge of a second piece of body panelling, jerked and snapped. Bugger! Now I had a broken drill bit poking out of the hole. It took quite some effort to remove it. Putting the rivet in wasn't easy either as the hole wasn't completely clear. I located another 1/4 inch drill bit that was as blunt as can be. Somehow I managed to make a hole for a rivet then put the rivet in.

At that point I gave up for the day. This was clearly not my day! After going inside I found voicemail on my phone that I should have received days ago but which mysteriously only appeared today though it had been sent days ago. Then a voicemail from my real job saying they'd lost a document and demanding another by two weeks time!

On top of all that, one of my online accounts was questioned by the account provider to the effect they don't believe I am who I say I am. Well, fine. I just don't care. I was threatened with account cancellation if I couldn't produce documentary evidence within 7 days to prove my identity. So... One of my accounts might mysteriously vanish. I just don't care!

Tomorrow I'll have to drive to Lowes for a new 1/4 inch drill bit. It will apparently be well over 100F tomorrow so heaven knows if I'll even be able to work outside the bus. The good news is I have 5 holes ready prepped to rivet patches over. After that I don't have any more bodywork holes to fill.

More good news - I'm just about ready to put primer on the whole of the dinette/kitchenette. There's stuff I'll have to move out of the way but it'll be nice to have it printed. I might prime the bathroom while I'm at it even though I still need to lay down one more board. No photos today - every time I tried my phone, the battery was flat!