CUSTOM FRONT DOOR BUILD w/ Keyless Entry! (Skoolie Conversion Guide #9)

Its hard to feel at home when you cant shut the door! In this episode, I show you my favorite way to solve the 'front door problem' all us Skoolie makers must face, this time with keyless entry!
My name's Chuck, I've been professionally converting buses for the last 7 years and was director of operations for a charter bus company before that but it's time for a change.....
IN THIS SERIES, follow along as I build a skoolie for myself, sharing my knowledge of buses and off-grid bus conversions along the way.
Follow me on instagram for more info
/ chuck.cassady
For paid consults, skoolie advice, solar help, and more, email
[e-mail]
Check out my shop
www.chromeyellowcorp.com
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#skoolie #offgridliving #busconversion

[@REGRETLYSS1]

It's incredible how you make something so daunting feel so approachable. These videos just keep getting better.

[@karylm23]

This, absolutely. Also? We should all have a "Tye" in our lives!

[@ChuckCassadyYT]

Thank you Alyssa :))))

[@joshbrownaz]

Chuck, thank you so much for your work. You have such a gift for this teaching. You bless us with your incredible knowledge and yet deliver it in a fun and humble manner. You are helping to make our dreams come true!

[@ChuckCassadyYT]

Thank you so much!

[@karylm23]

Really liking the detailed breakdown of your bus build. It's so satisfying to see those clean lines and talented workmanship. The standard for busbuilds has been set at your shop.

[@ChuckCassadyYT]

Thank you!

[@FB-111A]

Always look forward to Sunday Evening videos.

[@colleenbalch328]

Nice door, Charlie! One of the things I love about what you teach is that there’s always something I learn that applies outside of busses too. Bonus!

[@mmsmits2868]

Nothing like the sound of a solid door on a skoolie! Great job!

[@ChuckCassadyYT]

We agree!

[@joannast.germain5445]

That IS a mighty fine door! I have been watching (and re-watching, and taking notes) your fantastic videos in preparation. I just bought my bus, and am so excited to start the demo. I can't believe you're giving us all this help for free, thank you so much!

[@rodneyaiken1742]

Very nice job on the door and big props to who ever cut out for the lock set strike.

[@mo-tive2480]

watching the work you guys do really makes me want a skoolie!

[@WillMenesesHikes]

Super awesome job on the door!!

[@johnnylightning1491]

Nice door Chuck. Keep the good stuff coming.

[@michaelirizarry5037]

you guys are seriously top notch builders.

[@blaablooey]

I love the attention to detail and how you explain things. I might not ever get a bus but this is inspiring

[@Regionzen]

This is great information... Thank you so much for sharing it with the community!

[@ChuckCassadyYT]

Glad it was helpful!

[@kenknaell1290]

Chuck - great work and great video. You make everything look easy.

[@ChuckCassadyYT]

aw thank you! it wasnt always easy

[@CRLCRRLLTV]

Looking Solid!

[@jimmydickson8854]

It’s looking very smart mate jimmy from Australia

[@joeyvast]

Best Skoolie Builder on KZbin. thanks for the videos and all your hard work!

[@ChuckCassadyYT]

Appreciate that so much!

[@RavenSpirit917]

Genius you guys are amazing at what u can create so talented enjoy your videos. Looking forward to the completed bus conversion you all created for yourself !! Agree it is a beautiful door insulated and all ✌️

[@ChuckCassadyYT]

Thanks so much! stick around and subscribe and follow along!

[@devinrogers6877]

Man that's just awesome 👌 love the intro music too..it reminded me of watching This Old House on PBS lol ....good times !

[@ChuckCassadyYT]

That's the idea! Thanks for tuning in

[@mariemedina257]

Wow Alot work goes into making this e, very cool.

[@mariemedina257]

Wow! Alot of work goes into making this door..

[@ragulper]

It's a nice door, apart from the lock. I would have added an extra lock with a key to it for use when I'd be away longer times.

[@aaronelson8979]

That weather seal is great, I'm using the same thing on our engine cover. This technique looks really awesome, great video.

[@hmcfadin]

Wow, another informative video and an awesome door! Thanks for all the tips! You guys are so precise it’s obvious you have a huge amount of experience. Butyl is definitely the way to go on the window seal and is super easy to use. Thanks again an keep ‘em coming!

[@ChuckCassadyYT]

Thanks for watching!

[@buffalomitch7088]

Great job! Can you provide a link to the Roton hinge you used? Thanks!

[@DrSimonG]

This is such an awesome video! I’ve been learning tons from your videos so thank you for the info you’re putting out. I would probably have made some monumental errors without you sharing your methods!

[@ChuckCassadyYT]

thank you so much for watching!

[@Oinkpig5]

These videos are so helpful because I have always wanted a DIY project that i would use. I also hate the idea of an RV because they never have quite what you want and only have space for what comes with it making it difficult to live out of it long term.

[@TomBryan]

My Sunday evening wasn't complete without a video from you and your live stream Chuck.... Hope everything is okay.

[@ChuckCassadyYT]

Appreciate you! It was just a busy week so I didn't get to it but ill have more this week!

[@jimross7648]

As always you're giving me just enough information to make me dangerous cause, I don't possess the skill levels you and your team possess.

[@ChuckCassadyYT]

hahah ill need to put disclaimers before my videos ;)`

[@dougyoud5944]

Ordered the same lock. Thanks for the video!

[@ChuckCassadyYT]

Hope you enjoy it!

[@dougyoud5944]

@@ChuckCassadyYT has yours been working reliably for last year? How long do the batteries last for?

[@sierraautobodymustang9559]

nice jobs boys

[@EffieG-ez9tf]

Chuck, Beautiful door. You guys always do such fine work. If you wanted to add a simple handle to the inside and outside, how would you do that? Could you just use rivets to attach them to the door? Also, can you do a video on adding security to doors and windows? I am a senior woman and want to have extra security locks that can’t be opened from outside simply by breaking a window. Thanks. Don’t forget to show us how you filled in the open space along the hinged edge of the door. Thanks again.

[@rickwaggoner8479]

Love that

[@donpuryear91]

That’s a great door I’d like to build one for mine

[@karlwebber1090]

Have you ever done video on moving the skoolie door and installing pilot seat? By the way nice videos.

[@heepstuff2868]

Nice approach. Does definitely make sense to make the door fit the opening as it were. One thing that doesn't make as much sense to me is, why rivet the skin on, especially on the inside? The rivet heads will affect the quality of the bulb seal. I understand attaching the outer skin w Rivets, as it reflects the exterior character of the bus, but I would have welded the inner skin to the frame. Also, maybe it's just my OCD, but I wouldn't have mounted the window (or door) until it was painted.

[@MrJeep75]

Nice

[@vociferonheraldofthewinter2284]

Got links to the hinges and keyless lock? You are the best, man. If you had paid classes for every step, I'd buy in immediately. Seriously, I'd pay $250 cash right now for a detailed library, walking the students through an entire build process. I still don't know how to get the stupid heater out without breaking the whole damn bus. lol

[@TylerP823]

It’s beautful! What was the length of hinge you purchased? I imagine it’s bus specific but just out of curiosity

[@privatejjms1641]

Can you make a video detailing how you disconnected the air system for the old door?

[@akneemoose3383]

That green bus…WOW

[@nicholasphillips5406]

Is there any concern for galvanic corrosion between the aluminum hinges and the steel sides?

[@EquineHannaSomatics]

This is great! Less than a week traveling in my bus and I’m SO ready to ditch the Skoolie double door I thought I wanted to keep…

[@ChuckCassadyYT]

You're not alone!

[@EquineHannaSomatics]

@@ChuckCassadyYT my bus wanted me to ask you if you'd like to build him one of these custom doors while you're here in Oakridge for the Bus Fair? Maybe could even add it to the lineup of workshops on offer?

[@9-5Adventures]

I think I’ll try this without welding (do not know how). Drill the frame right into the bus. And use 90 degree angles to frame the door

[@stevewicker984]

Boy I wish you would have built my entry door on my Tiffin class A !

[@maryhight6030]

Great 👍🎉❤

[@BolonaJoe]

Thanks!

[@BolonaJoe]

Would love to have you down to look at our bus! I’m quite sure your busy but do you plan on staying in CO or relocating? We’re in Littleton

[@ChuckCassadyYT]

Id be happy to, I do many paid consults. Ill be in Denver at least a few more months! email me [e-mail]

[@1jaxgirl]

hey :) I see that Crown in the background... did you happen to do a roof raise on it? If so, how difficult was it to match the original curved profile of the bus? I'm planning on a Crown for my conversion and want to maintain that "twinkie" look when I raise the roof. Thanks!

[@EffieG-ez9tf]

Will you be adding any windows to the sides or back end of your bus?

[@sealguy77]

Hey Chuck, love your videos. I was wondering if you ever had issues with the steel frame and 2x1" rectangular tube with the aluminum hinge. I know mixing steel and aluminum can cause corrosion and it doesn't seem like you used any insolating materials between them.

[@ChuckCassadyYT]

It's painted beforehand, I'm sure given a few decades you might see isuues

[@JoeDWhiteTalks]

Hi Chuck, Do you remember the model number of the roton used in the video?

[@naturesguyed9388]

Hey Chuck! Struggling to find a hinge like this. Do you have a link or store you get it from. Doing both a front a rear door soon! Appreciate it.

[@niveknospmoht8743]

Was it you guys that moved this door back on the other side of the latching pillar for passenger seating?

[@ericterry1148]

How did you cut the inside corners for the window?

[@katiefleming6665]

Hi Chuck. I’m getting ready to tackle this project I’ve gathered all my supplies and I’m ready to give it a go. One quick question though. What did you use as spacers on the 1x2 square tube? I’m a complete newbie at welding and not sure how to go about that step. Thanks!

[@ChuckCassadyYT]

i just used some metal scraps i had laying around!

[@markb.1259]

Really excellent door job! How do you keep galvanic corrosion from eating up the dissimilar metals (aluminum hinge and steel door frame)?

[@ChuckCassadyYT]

We paint the steel,but I'm not too worries since the screws that come with the hinge are steel, they must think it's no big deal

[@DrSimonG]

I’m considering putting some kind of thin, inert gasket between the 2 metals, like a thin layer of rubber or plastic... but like Chuck said, I don’t think it’ll be too much of an issue.

[@reddsmorris7053]

Nice door. Only problem I had was is with my eyes. I have eye delay and the camera was moving just fast enough I couldn't see what the hinge side was and how it was built up. But good job

[@firecop7912]

Hello, I have a question, Really thinking about buying a Motor home Or a used school bus preferably a 72 passenger because I'm interested living in it as my home. My question is what would be the average conversion cost? I know there are different needs regarding a bus conversion which make up the cost difference, I get that. But just an idea would be very helpful in decision making. Thanks!!😊

[@DrSimonG]

Hey Chuck, love the video! Quick question - did you remove the screws that hold the original door frame side trim in place? I’m guessing you didn’t need to because the new frame you welded on is far enough from the original frame to allow clearance for the screw heads, but I’d be interested to hear how you addressed that issue. I’m considering grinding the heads off and welding them to avoid play in the trim panel, but perhaps I’m over-thinking it... what did you do? (Hopefully you didn’t cover that and I just missed it in the video... 😬)

[@ChuckCassadyYT]

Not totally sure which screws you're referring to--the ones inside the door jamb or on the outside face of the door frame but the outside ones are cleared because the hinge sets the door out far enough. There actually weren't any screws inside the jamb of this door to start with, but in the past, we've removed them and plug welded the hole. Hope that helps

[@DrSimonG]

That totally helps! I thought I saw screws on the inside of the door jamb but I might have been hallucinating! My bus has them all down the inside so I’ll remove them and plug the holes. Thanks for a SUPER fast reply!!!

[@BryantBeers]

I'm planning on building this door this coming weekend. Do you happen to know which model of Roton hinge you used? I see they have many different styles. Also, where did you source that RV window from? I heard you say it was dual pane insulated. I have a hard time finding them on Amazon. Thanks for the awesome videos and inspiration!

[@veracutbear2445]

did you ever find out which hinge was used? i had the same question.

[@BryantBeers]

@@veracutbear2445 yes actually. It was the Roton 780-110HD. At least for my application I used that one. There is another 780 model that has a wider attachment surface that could work better on the 1in 1/4 frame. Still, the 780-110HD supports 200lbs. We found the hinge at DoorCloser for $89, but it's the anodized bronze aluminum version, and not jus the bare aluminum version.

[@veracutbear2445]

@@BryantBeers thanks man

[@johnsont963]

do you have a part number for the edge bulb , and a source to purchase from?

[@ChuckCassadyYT]

Amazon!

[@kalrobbins2811]

Once the door has been fitted as a custom door, is it wide enough for a full size washer/dryer or refrigerator?

[@ChuckCassadyYT]

It depends on the bus, these custom doors end up bigger than thr stock one it replaced so that helps. There is also usually a back door

[@JaySoftail14]

Do you have a link for the door hinge? Everything I have found is for a 1-3/4” door or bigger. TIA!

[@ChuckCassadyYT]

this is the same, we just grind off the extra!

[@trashpandaent1473]

Link to this Hinge please???😊

[@TehGnomeWorks]

Would it be possible to get a part number or source for the door hinge?

[@ChuckCassadyYT]

Its a Roton door hinge from amazon

[@bmxican1023]

Got a link/product name for that latch? Looks a lot better than a regular one from off the shelf at Home Depot lol

[@ChuckCassadyYT]

Search keyless rv latch on Amazon. I believe it's called Tiger Latch or something

[@NoClocks.NoCalendars]

Have you considered providing Amazon links to the products you are using so that Amazon pays you a small percentage for every purchase people make through your link. Or is the percentage so small it's not worth it? Nice door btw!

[@ChuckCassadyYT]

Ive definitely considered it, i just need to sit down and make it happen!

[@harrykrimmel1291]

Please give a ballpark cost to raise a roof 12 inches and a custom door. I do not have a garage but I want to do my own bus. Also, it I buy a bus can I being it to you for the above ?

[@michaellassley30]

Are the windows in the door double paned?

[@ChuckCassadyYT]

Yes

[@christyperez94]

So I’m curious how much you would charge me to make me a door like that? I’m a first time builder that is making all the mistakes you tell us not to make but I already have her and have to do the best I can with her 😂❤😢🤷‍♀️

[@bookreaderlabarr]

Link for hinge

[@sasquatchskoolie8081]

Have you built a traditional wooden door...and what problems did you encounter...thanks !!!

[@ChuckCassadyYT]

No! The wood would have a hard time surviving the road

[@karenlara9739]

😄🥰

[@bloodybonescomic]

How does the keyless entry get power?

[@ChuckCassadyYT]

A battery

[@bloodybonescomic]

A battery works. I saw that electrical connector and thought it had to plug into chassis power.

[@865style]

With everything that's happening I could see this type of business going two directions. Personally I think this could become a booming business. Because of the insane prices for everything people have a lot less money to spend on a house, appartment, or whatever. By having something like this built that can run on its own from solar energy is huge imo. The economy is not going to get better until biden is out of office. The other possibility is will people want to invest in something like this when we're in such a horrible economy. Obviously people will have to accept the fact that they will have a smaller place. I dont know how many people actually feel about this type of thing though. You're already at 10k subscribers so I'd say they like it to some degree.

[@ChuckCassadyYT]

Thanks man. There is very high demand, but that's never been the problem. Its the reality of how much overhead costs to run the shop, increasing materials costs, decreasing availability, and the fact that my skills are worth a lot more if I focus on just a few areas, rather than full conversions. Mostly, Im burned out on running a business where every dime is earned by hard work when people can get rich sitting on their butts working on laptops. If Im gonna be poor, im at least gonna relax haha. thanks for watching, these videos make me happy

[@pokquat1462]

Is there a legal way to tear a hole in the wall of a bus and make another door?

[@ChuckCassadyYT]

Yes, we do it all the time

[@pokquat1462]

@@ChuckCassadyYT Do you know any videos I can refer to? That is something I would want to fall back on if I can't find a bus with a wheelchair lift in the spot I want it. Thank you.

[@jeniphersocha6896]

Side bulb 🤣

[@hoangpham4468]

I think hard step is mount the hint but you did not show that step

[@ChuckCassadyYT]

It really isn't, these hinges have an indexed lip

[@officialpoa3171]

*Piano hinge.*

[@ChuckCassadyYT]

I prefer the commercial door geared hinges over a piano hinge

[@officialpoa3171]

*Same product, different market, therefor, different name... Its like selling a provst h35 as an entertainer coach for $500k, then take the exact same bus and sell it as a charter coach for $75k*

[@ChuckCassadyYT]

I see what you mean, but it is very different from a piano hinge!! Look up a Roton commercial door hinge. Quite different

[@officialpoa3171]

Yeah we use them when ever we build a recording and mastering studio or a sound stage. They also fornsome reason like tobuse them in hospital builds, i suppose its al about the mass of the door.

[@krakenengineer]

How many people does it take to install a door lol

[@ChuckCassadyYT]

Three!

[@krakenengineer]

@@ChuckCassadyYT It is a steel door =D

[@peterkangas3127]

A bus door is Bifold not one peace

[@ChuckCassadyYT]

I'm not sure I follow you. I've owned many buses with one piece doors. Crown buses and MCI buses use one piece doors.

[@scooter1748]

this is beautiful but i would like to point out how poorly those camper latches and locks work. for one, they pretty much all use shitty keyways and are often keyed alike. some use the universal ch751 key still. (not the model pictured, i was mistaken.) seen too many clapped out, broken-into-two-thousand-times tweaker campers. again, love the door, hate the latch and lock. not yet sure what i'll do about entry, since i like all of the original controls (door, crossing bar, stop sign) but whatever I do, i'll probably eventually fabricate a door and use an electronic fail secure bolt w/ manual backup. i have a model from YLI Electronic in mind, they seem to use a half-decent keyway. good enough to meet the bare minimum at least. either way, just kind of coming up with ideas for now. learning all i can before jumping in and getting a bus.

[@ChuckCassadyYT]

A lot are shitty. I say that locks just keep people honest, you're always one broken window from someone getting whatever they want! I'll have to check out what you mentioned

[@scooter1748]

@@ChuckCassadyYT very true haha! i tend to needlessly obsess over the most obvious point of entry. at least having a half-decent bolt on a door will deter the lowest skilled thieves short of the window breaking you mentioned* and malicious family members. the ones i'm looking at are almost certainly overkill both in terms of robustness and price ($80-160 USD from china, lol but they're very pretty) the other nice thing though is you can control them however you please. switched by a development board running a custom application (ie via a phone app) or with the common rfid access control modules + request to exit switch. i intend to set my bus up with the same level of diy'd home automation and security as a normal house, since i'll be away quite a bit yet live in it full time when i'm not resetting on the road. btw, was there ever a part 10? the playlist says one video is unavailable and hidden and seems to jump from part #9 to #10.5.

[@idowanna837]

I have a bus I'd like to show you and have a discussion regarding said bus. Can I get your contact information so I can email or txt you the link?

[@ChuckCassadyYT]

you can email me at [e-mail]!