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Stesso

Stencil Application and Layered Painting

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Inside The Most Expensive RV Paint Job In The World! Prevost Liberty Coach (2.6 Million Dollar RV)

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What happens here

The custom paint shop utilizes a cross-draft paint booth where two buses can be worked on simultaneously. The air flows from the back of the shop to the front. To manage overspray and ensure quality, painting starts from the back of the bus and moves forward, following the airflow. The intricate designs are created using large-format stencils. These stencils are precisely cut and laid out on the bus, using specific reference points like door seams and body lines to ensure accurate alignment. The stencils are printed in multiple strips due to the bus's size, and different colors of pinstripes and other patterns are applied in layers. The process is compared to a 'coloring book' where lines are first established, and then colors are filled in.

Goal: Precisely apply complex paint patterns using stencils and a layered approach.

Tools and materials

  • Ladders / Scaffolding — Providing access to different heights of the bus
  • Paint Sprayer — Applying paint layers to the bus
  • Custom Paint Colors AkzoNobel Sikkens — Creating the various patterns, including goldish and white pinstripes
  • Masking Tape — Securing stencils and masking off areas
  • Stencils — Creating precise paint patterns and designs

What they say

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all windows so we prep them down in this end of the building and all that that's our painting bring in air here [Music] around the other end we're doing a couple of buses at a time easily you know and then i'm usually even fixing one somewhere here in the middle doing a repair buses if it's cross draft do you have a system where you like paint stuff on the back first and then work to the front or oh absolutely how does that work well i like to follow the airflow so as much as we can we start to spray in the back and we follow that airflow forward so all the yellow you see on here that is the stencils that we produce up front that's what lays out the paint job it's like it printed as one big piece and put on there so all the spacing is the same or they laid out individually that it gets printed in basically three strips because of the size of the bus the size of the material we can deal with so it takes three rows of material to get that laid out sized up where there's points that are always on the bus there's intersections here that are on every bus and we have little little hexes that we drop right on there that's how we line all this up so we have two different colors of pin stripes going on there right now we have uh kind of this uh goldish color pinstripe and we have white pinstripes both on here and that's what we're working on right now we're getting all that laid out here this one here is getting laid out also this just has one color of pins on it see all these pencils going on that just gives us our layout so right now we're getting ready to spray the whole front of this bus black we just hang a little bit of paper so we can get ready to start spraying that and then we'll cover that color up in a sense it'd be about like a coloring book once we have all the lines now you're filling in your blanks in between all the lines [Music] a blown up rendering of this just so we can get a look here a little better at the baits and the things going on but you kind of see all this coming together right now you can see all these stripes and then how much work is going to be left inside of them yet from start to finish how long does one of these take um liberty picks up a finished bus from us every three and a half weeks so they're bringing a brand new bus and they're picking the finished one up i've always got two buses of theirs in process i'm painting one and i'm prepping one as soon as we finish one they bring me another brand new one to start on years ago we…

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