2002 Chevy short bus build

[Tstege83]

Made some progress and figured I would start a simple build thread here.

Chassis 2002 Chevy Collins w/350 and 65k miles. Has single rear wheel (big plus for me) weighs 6000 as I have it now with a full tank of gas.

Bus came factory white and is only 66” inside

Mods as of now.

-completely gutted and deleted wiring and high marker lights (to prevent leaks)

-removed windows and skinned sides with 18 gauge

-added RV/trailer windows with screens

-added Vetus Magnus 25” sailboat hatch/sunroof (roof access

- maxxair vent fan

-custom solid steel front door with insulation and 2 windows

-1 1/2” professional spray foam

-have 2 150 amp AGM batteries, 310 watt solar panel, and rack system so I will have the panel in front and a deck in back.

Will be working on finishing over the next month.

Future mods

-extend rear bumper 24” and add 2 truck boxes I scored for storage in the rear. I will also add some decking for an outside shower area. And place to carry 2 bicycles.

-finish painting exterior door will be green, rub rails black, roof all new coat of white.

-interior birch 1/4 ply walls and ceiling

-small kitchen, bed area, and dinette

-add passenger seat

-2” heavy duty coil springs up front with 16” black steel wheels and new AT’s

-install the under mount propane tank I have behind drivers seat where AC fan use to be.

 

[zelseman]

So many questions...
Are you worried about maxing your GVWR? How much does it weigh after everything you have done? What was your process for skinning the Windows?

 

[Tstege83]

Sorry I didn’t follow up with anything. I’m not really worried about weight at all. It was weighed before I stripped it out and it was 6200 pounds. I figure with all the seats and metal, AC, heater, wiring, plumbing, I took out it should be about 400 less now if not more. I’m visiting family and working on it full time now. Here are some updates photos.

 

[Tstege83]

The process for skimming was I removed all windows on both sides. Got a sheet metal shop to cut 2 10 ft strips of 18 gauge steel. Then just undid the top rub rail rivits. Used a liquid nails bonding type metal caulk and slid them up and in under the rub rail. After I just riveted them in place with closed end rivets.

Installed the flooring which is a floating floor with sound deafening rubber on it from menards. There are no seems on it.

With all the pine and the spray foam the bus gets warm and stays warm.

 

[Tstege83]

For the bumper I used 2 ranch truck toll boxes and mounted them up using angle brackets from northern tool made for truck boxes. Then I put cedar decking so we have a platform for bicycles and cooking.

 

[Tstege83]

Got the bed platform in today. It’s really sturdy. We have a queen short mattress so it’s 60x75. The width of the bus inside the walls is 76 1/2 so it worked out perfect.

 

[Tstege83]

Finally finished the bus. I need to take better pictures but here are the ones I have. Below are some features.

electrical- 2 150amp hour batteries
-Renogy charge controller
-315 watt panel up top
-sterling battery to battery charger
-1200 pure sine wave inverter
-Truck fridge TF130 DC fridge
-LED lights, cigarette plugs, and dc fuse block.

water- 42 gallon tank with sure flow pump, sink, 5 gallon grey water, and on demand shower mounted to back door.

propane- under mounted Manchester tank. Line to the back with quick release for grill and shower.

 

[Tstege83]

Videos 1 and 2 quick rundown of the build

 

[Cruisn]

Well done build man

 

[Tstege83]

Well done build man

Thanks it was difficult but well worth it.