Josh’s Magic Bus...1946 Flxible Clipper
Robert Abercrombie

A New Challenge is Found
Flxible Clipper 7312 was originally sold to Mid Continent Coaches of Oklahoma in 1946 and remained an inner city bus until 1966. The bus was then professionally converted into a motor home by Coach Works of Illinois and spent the rest of its life in New Mexico. When Bob Abercrombie, Toledo, Ohio, read a classified ad that the bus was for sale, his restoration desire was kindled anew. After 25 years spent restoring four cars, he was ready for a change and the Flxible Clipper bus could be it. After all, he had experience with a friend’s bus restoration not long before. The first question he asked the owner, “Is it rust free?” Bob purchased the bus sight unseen and had it relocated via a lowboy trailer with help from the previous owner.
Help from the Oak Park Gang
Bob was one of the founding members of “The Oak Park Gang” Car Club, whose members would provide advice or assistance in the restoration/rejuvenation project of the Flxible Clipper 7321. After arriving in Toledo work began on the 25BR46. Terry Smith, a prior NASCAR mechanic and owner of Terry’s Automotive, a local automotive repair and speed shop, performed all the mechanical work.
The Drive Train
First, the engine along with a manual Spicer transmission was removed and scrapped. Terry located a dump truck with a Chevy 427 tall block. After totally rebuilding the engine, it was time to revamp the engine compartment to facilitate clearance for an automatic transmission.
The entire slide rack was removed to provide adequate clearance. Removing all the steel and installing a new cross member accomplished this plan, providing the needed area. The slide rack was designed by Flxible years ago to slide the old Buick straight-8 out the rear hatch and change the engine on the road without taking the vehicle to a garage. Now the Chevy 427 engine had to be positioned at the extreme end of the engine compartment and the cooling fan eliminated. Proper cooling was obtained by anchoring two fans, equaling 4600 cfm, to the backside of the radiator. A temperature switch was installed to automatically control the fans and a bypass switch was installed for manual control.
Coupling a fresh Allison AT545 to the engine gave enough clearance for a new drive shaft. A transmission cooler was then mounted on the front side of the main radiator, which mounts directly over the engine and the pan was modified to accept a sending unit for the temperature gauge. At this time all of the gauges were replaced with Auto Meter Z series units.
Axles, Wheels, and Brakes
After the engine was installed, it was time to check out the air brake system. At this time Terry and Bob decided it would be better to upgrade the both axles to improve stopping capabilities and parts’ procurement in the future. Terry located a 1999 Thomas bus with the right parts to upgrade the vintage system. The rear end (pusher) had a 4:11 ratio; and after installing new 27” tires with aluminum rims made for an ideal road gear, high gear shifts at 47 mph. The bus gets 8 to 10 miles per gallon depending on driving conditions, and it has plenty of torque.
Both the front and rear axles were refurbished and installed, along with drilling new holes to fit the present springs. A new 14” drive shaft was fabricated to connect the transmission to the rear end.
Finishing the Chassis
When it came time to review the steering, Terry and Bob again agreed that rebuilding the old power assist steering would not be as good as updating the unit to a modern power steering pump. A few days later Terry located a steering column from a 2001 Kenworth truck with very low miles that could be modified to fit the Flxible. The new tilt steering column was installed along with the gearbox and cruise control with only minor alterations.
Another club member, Bill Ehrsam, and his friend Jeff designed the drive shaft. Bill, an old national drag strip champion from 1963-68, knew what it takes to provide smooth acceleration and proper torque to the rear wheels.
New air bags were then installed on all four springs with individual regulators that can be adjusted independently for different load conditions. The bus now has a new rolling chassis with a vintage body.
The Body Needed Help
Keith Spaulding started on the bodywork at the same time Terry was working on the mechanical work. Keith was a body man “back in the good old days” in the early 60’s, when customizing was very popular. Joe Yerg, another “youngster” and a member of the club, assisted Keith by stripping the entire body. Keith removed the old panels around the windows and new steel was installed, eliminating a lot of metal repair. Over 700 blind rivets were replaced to obtain originality. Pete Bailey (P.B. Fabrication), another club member, was instrumental in locating many of the fasteners, specialty steels, and aluminum. Although the bus was virtually rust free, there were dents and access doors that had to be repaired or replaced. The rear door was eliminated and other compartment doors closed in to give the Flxible a streamline look. After five months Keith was ready to start priming and painting. Bob picked out a beige and olive-green combination and new stainless was ordered for the sides.
During this same time Ed Cherry, the club president, was working on installing the new oak ceiling. As a retired mechanical/construction contractor, Ed was very knowledgeable in designs of different components and woodworking. He replaced the air conditioner with a low profile unit so the clipper would clear a ten-foot door. Other woodwork included replacements of the refrigerator, flat screen TV, furnace, rear bed compartment, and floor modifications.
Ron Valerius, Unlimited Automotive Service, removed all of the side windows, buffed all of the frames and installed new tinted glass. He then started to upholster all of the cushions and to make new curtains. Bob wanted to keep to the nostalgic look of the original conversion intact as much as possible, so much of the birch woodwork was revarnished and not replaced with different material.
When it came time to have carpet installed, not many carpet companies want to install carpet in RVs because of the limited square footage. Fortunately, the club had a member, who owned a carpet business in Lambertville, Michigan. Tom Townsend, a bus owner himself, took pride in installing the carpet. Even the original 1946 bus license plate, was located by Lenny Fetterman, the club’s license plate guru.
Electrical Rewire
Bob with Roger Grant performed the electrical work. Roger, a retired GM electrical supervisor, was very helpful in the design and installation of the various systems. All electrical wires were stripped and new wire installed. All circuits were installed, utilizing relays to eliminate voltage drops across the switches. A three-position selector switch (Noco model SW5500) was installed in the engine compartment to facilitate selecting one, two, or both batteries to be used for charging or camping. Heavy disconnects (Moroso 74102) were installed to the negative side of each battery to have the capability to completely denergize the system.
An Inteli-power 9200 series, 60 amp, DC inverter was installed to maintain constant voltage while hooked to shore power and trickle charging. It can also be used in conjunction with the house generator in the event of the alternator failure. The Inteli-power converter constantly monitors the battery voltage, automatically adjusting the converter output voltage to provide the proper voltage for fast recharges and long-term maintenance. The unit was wired in parallel with the alternator, so whichever unit is putting out the most voltage, it will switch over automatically. A Wirthco 120-amp circuit breaker manual reset was also installed in series with the alternator for added protection.
DC and one AC panels were installed to protect all circuits when camping and all power to the ignition system is isolated. All of the appliances were put on separate circuits, identified, and labeled with the proper amperage. The lighting system is either 12volts or 110 depending on the hook-up.
A Parallax model ATS 30 automatic line generator (30-amp) switch was installed to be able to switch from shore power to generator without throwing any switches. The AC was polarized and different configurations of plugs and pigtails were made up to be able to accept any situation. Bob, an old car buff, attends a lot of antique car rallies and has learned that standard hook-ups are sometimes not available.
Don’t Forget Plumbing
To upgrade the plumbing system, Bob, being a retired Chrysler maintenance area manager, knew this was up his alley. All of the existing copper lines were replaced with plastic. Valves were installed to back flush, isolate, and drain the system. A new Flojet water pump, rated a 3.2 GPM, was installed along with a check valve for automatic switching of shore water.
Make it Real
The club’s historian, Jr Showman, who has worked on Flxible buses for more than forty years, was very helpful with the technical information and parts procurement. Jr lost his leg over a year ago, but it hasn’t slowed his down a bit--especially working on and preserving old Flxible buses. The last time Bob call JR for advice, JR was underneath his son’s Clipper, working on the engine, but he was also getting ready to drive his own bus to a rally.
Finishing Magic Touches
Another member, Bob Peinert, provided “Memory Lane” a complete slide show presentation with captions to be used at shows and club events. Bob is a local funeral director.
The Clipper’s name “Josh’s Magic Bus” honors Bob’s five-year-old grandson, who loves buses, old cars, and trains. The ‘magic’ part was derived from club members, who have learned that whenever something was needed for the bus, it magically appeared. Just ask Terry, who went through two 427 blocks that were not rebuildable and every one was searching for a good core. Overhearing the conversation, club member Paul Clawson, announced, “I have a good wrench motor in my garage. Come over and get it.”
As for the name, since the bus was built, Bob has a new granddaughter, so if you see a similar bus rolling down the highway with “The Oak Park Gang” logo on the side, look for the names “Josh and Sydney” on the marquee. It’s probably the Magic Bus Flxible Clipper 7312, a real tribute to teamwork and talent.