2001 5.9 Cummins Starter Problems and Finishing the School Bus Floor

Starter Problems

So the starters in a 2001 Thomas School Bus sits right below the fuel purge valve on the fuel filter. So the other day, we left the fuel purge open and bathed the starter in diesel fuel.

Now the bus doesn’t start.

Floor Work

These School Buses come with seats in them. Each seat has 4 bolts going through the steel floor of the bus. When we removed the seats, all the holes were left over. I was thinking about welding them shut, but the cutting and welding would have taken all day.

Loctite Heavy Duty Epoxy Quick Set 8-Fluid Ounce Bottle


Copper pennys seemed like a great solution. Each hole plug costs about 1 cent and we already had a bunch on had. We used about half a box of epoxy so the project probably cost us about $8 in not counting the paint.

Steel Paint

Here’s a link to the paint we used:

RUST-OLEUM 242256 Professional Gallon White Gloss Finish


It’s not the cheapest paint, but we’re trying to build our bus out so that it will last 100 years. Spending an extra few bucks on the nicest paint now will pay off in dividends for years.

If you’re going to use this paint, make sure to let it dry for at least 24 hours. It stays sticky for a long time. When it’s sticky like that, it has the potential to rip if you spin around on your feet. After 2 days, it acts as one with the metal. I’m very happy we decided to paint the floor with two coats of this paint.

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