Roof Hatch Installation-Part Deux

Here is the what I accomplished today with the roof hatch.
Armed with Dan's Sawzall, I removed the inner roof skin.

It wasn't easy. The inner skin is slightly thinner metal than the outer skin.  The rapid sawing motion of the blade cause the metal to vibrate and flop around.  I used a bar to keep the shaking to a minimum so I cut the final portion.

Now I had a hole all the way through my roof.  (Gulp)
I test fitted the hatch frame.  I placed the inner skin temporarily over the top to keep some dust out.

After many different test fittings and micro adjustments I finally got to a position I felt was just right.  I pre-drilled all the holes for the hatch.  Then put down butyl tape around the perimeter of the hatch and over the pre-drilled holes.  I silicone caulked the inner corner of the frame. Then I put the frame down one final time and bolted it down.  You can clearly see grinder marks from when I removed hatch from the other bus.

After the screws went in I covered the outer seam and the screw heads with some butyl caulk.

This stuff is the best to use on RV roofs.  It is also the messiest caulk I have ever used.  It is rubbery and not easy to shape with your finger.   But it is more durable and flexible than silicone.  I really gobbed this stuff around the outside.
Here is a pick after I installed door to frame.  This is hatch door closed. (Cosmetic stuff like washing fingerprints off and fine tuning a few other things will happen later)

Hatch Door Open (driving height, not escape height)

Inside view of hatch before interior trim was added.

After some trial and error, I got the trim to fit the curve of the bus ceiling...pretty much.  Ignore the slight cracks in places between frame and trim.  Another cosmetic issue for later.

 I do believe the professional grade installation is pretty tight...and it really makes my curtains pop.

I have a few more things to do to fine tune it but I am really pleased with the finished product.   One more big project under my belt and checked off my list.

 I have to run now and put stuff away and pack.  I am going a few hours away for a job fixing up a house tomorrow morning.  Dan, you'll remember him from my free diesel post..he has been providing work for me all week.  Started out pulling Turbo chargers out of the buses that were salvaged and doing some other things.  Dan took me for a drive through, mini tour of downtown Denver last night.  Very cool downtown area, lots to do.  Anyhow, I will be gone for a few days.  I am leaving the bus here at the storage lot, but I get to bring Nala along with me.